WO2009016335A1

WO2009016335A1 - Battery arrangement

Info

Publication number: WO2009016335A1
Application number: PCT/GB2008/002097
Authority: WO
Inventors: Anthony James Donaldson; John Paul Mort
Original assignee: Rolls Royce PLC
Current assignee: Rolls Royce PLC
Priority date: 2007-07-27
Filing date: 2008-06-19
Publication date: 2009-02-05
Anticipated expiration: 2010-01-27
Also published as: GB0714742D0

Abstract

A battery arrangement (10) comprises a housing (22) and a plurality of electric cells (12) arranged in a plurality of layers (14, 16, 18, 20) within the housing. The layers of electric cells define a duct (34). A plurality of connection members (36) connect the cells electrically to one another. A terminal assembly (37) is provided on the housing to connect the battery arrangement electrically to an article. Some of the electrical connection members extend through the duct (34) to electrically connect the cells (12) to the terminal assembly (37).

Description

BATTERY ARRANGEMENT

This invention relates to battery arrangements. It is well known to use rechargeable battery arrangements in vehicles, such as submarines and ships, to provide power to drive the vehicle.

However, known battery arrangements are heavy and bulky and in order to provide the necessary power a large number of these battery arrangements are required. This means that the compartments holding them need to be robust to support the weight and large to hold the volume of such battery arrangements as are necessary.

According to one aspect of this invention there is provided a battery arrangement comprising: a housing; a plurality of electric cells arranged in a plurality of layers within the housing, wherein the layers of electric cells define a space extending within the housing; a plurality of connection members to connect the cells electrically to one another; and a terminal assembly on the housing to connect the battery arrangement electrically to an article wherein some of the electrical connection members extend through the space from the electric cells to electrically connect the cells to the terminal assembly.

Preferably, the layers of electric cells are arranged in a plurality of layers, wherein the layers are arranged one upon the other. The aforesaid space may extend vertically through the layers. The space may be a duct.

The housing may comprise inner and outer walls, defining a gap therebetween. The housing may further include thermal insulation between the inner and outer walls. In one embodiment, the thermal insulation may comprise a sintered vacuum material. The sintered vacuum material may comprise calcium silicate, which may be calcium silicate powder microporous boards. The sintered vacuum material may be compressed. The thermal insulation may further include material to reduce infra-red transmission, such as iron oxide and/or silicon carbide. In another embodiment, the sintered vacuum material may comprise titanium oxide. The housing and thermal insulation may fully enclose the cells of the battery arrangement, except for the electrical connections passing through a port in the upper part of the housing.

Each of the electric cells may comprise a salt material, such as sodium chloride or nickel chloride, and may further comprise a metal, such as nickel or sodium. In the preferred embodiment, the cells may comprise a nickel/sodium chloride cell. Examples of such cells are known in the art and battery arrangements formed of such cells are generally referred to as ZEBFlA batteries.

In the preferred embodiment, the battery arrangement may comprise two, three or four layers of the electric cells .

Each of said layers may comprise a leakage sump upon which the cells are disposed. The leakage sump may comprise an insulation material to insulate each layer from the layer below. The material in the leakage sump may be a corrugated material.

The duct may comprise a support member, through which the connection members may extend. The support member may provide support for each layer of the electric cells. The support member may comprise a tubular member.

Heating means may be provided on each of the layers to heat the electric cells of the respective layer. Preferably, the heating means is provided at the top of each layer to heat the electric cells from the top down.

The heating means may comprise a heating tape.

An embodiment of the invention will now be described with reference to the accompanying drawings, in which: Fig 1 is a sectional side view of a battery arrangement, with a top region omitted;

Fig 2 is a top plan view of a layer of electric cells within a battery arrangement, showing connections between cells;

Fig 3 is a top plan view of one embodiment of the top region, omitted from figure 1, of a battery arrangement such as shown in figure 1.

Fig 4 is a sectional side view of one embodiment of the top region of the battery arrangement shown in Fig 3;

Fig 5 is another sectional side view of a second embodiment of the top region of the battery arrangement shown in figure 3.

Fig 6 is a top plan view of a compartment of a vehicle holding a plurality of the battery arrangements shown in Fig 1.

Referring to Figure 1, there is shown a sectional side view of a battery arrangement 10 comprising a plurality of electric cells 12, arranged in a plurality of layers 14, 16, 18, 20 disposed vertically relative to each other. Figure 2 shows a top view of the cell layers 14, 16, 18, 20 in a battery arrangement 10 which is the same as the first mentioned battery arrangement, with the exception that the number of cells differ. The battery arrangement 10 comprises a casing 22 comprising an inner wall 24 and an outer wall 26 defining a space 28 therebetween. The space 28 contains an insulation material and is evacuated of air to provide a vacuum. The insulation material is a sintered vacuum material, such as iron oxide and/or silicon carbide, or titanium oxide.

At the bottom of each layer 14, 16, 18, 20, there is provided a leakage sump 30 to collect any liquid that leaks from the cells 12 disposed thereon. Each leakage sump 30 supports the cells 12 disposed thereon. The leakage sump may hold a corrugated material. The material in the leakage sump is also an insulating material to insulate the cells 12 disposed on each leakage sump from heat from cells 12 beneath, and to insulate the cells 12 beneath from heat from the cells disposed on the leakage sump 30.

A heating tape 31 extends across the top of each layer 14, 16, 18, 20 of the electric cells 12 to bring the electric cells 12 up to the required operating temperature. Each layer 14, 16, 18 and 20 of the cells 12 includes a tubular member 32, which extends generally vertically in a generally central region of the cells 12 of the respective layer 14, 16, 18, 20. The tubular member 32 in each layer 14, 16, 18, 20 replaces some of the cells 12 at the same horizontal location. Thus, a duct 34 is defined through the layers through which a plurality of elongate electrical connection members 36 extend to connect the cells to a terminal assembly 37 at the top of each battery arrangement 10. In the case of the embodiment shown in Figs 1 and 2, each tubular member 32 replaces four cells in the respective layer 14, 16, 18, 20.

Each tubular member 32 provides support for the cells 12 in the respective layer 14, 16, 18, 20.

A heating tape 31 extends across the top of each layer 14, 16, 18, 20 of the electric cells 12 to bring the electric cells 12 up to the required operating temperature.

The tubular members 32 define the duct 34 along which a plurality of elongate connection members 36 extend vertically to connect the cells to a terminal assembly (see Figs 3, 4 and 5) at the top of each battery arrangement 10. Each cell 12 of each of the layers 14, 16, 18, 20 is electrically connected to adjacent cells 12, and at least two of the cells 12 adjacent the tubular member 32 are connected to the elongate connection members 36. The connection of the cells 12 of each layer 14, 16, 18, 20 to one another and to the connection members 36 ensures that all the electricity generated by the cell, 12 flows to the connection members 12.

The electrical connection between adjacent cells 12 are effected by a plurality of connecting elements 38, which also provide the electrical connection to the elongate connection members 36. If reference is made to

Fig 2, one example of arrangement of the connecting elements 38 is shown in Fig 2, but it will be appreciated that many other such arrangements could be used.

As can be seen from Fig 1, the connection members can connect one layer to a layer above, or can connect each layer to the terminal assembly 37.

Referring to Fig 3, there is shown a top view of a battery arrangement 10, showing the terminal assembly 37.

The terminal assembly 37 comprises a connector 40 to connect the terminal assembly 37 to the elongate connection members 36. The connector 40 is, in turn, connected to an isolation switch 42 via battery management instrumentation 44. The isolation switch 42 is used to isolate the respective battery arrangement from other battery arrangements, for example to carry out maintenance. The isolation switch 42 is movable between a live position shown in solid lines in Fig 3, and an isolated position, shown in broken lines in Fig 3.

The terminal assembly 37 also includes an integrated protection unit 46 to cut power from the battery arrangement 10 in the event of problems. The integrated protection unit 40 provides electrical connection between the isolation switch 42 and a cable 48 along which the current flows .

Referring to Fig 4 there is shown a part-sectional side view of the terminal assembly 37 shown in Fig 3. As can be seen from Fig 4 the majority of the components of the terminal assembly 37 are held within a recess 50 of a holder in the form of a top box 52 having a hinged lid 54 and side walls 56. Two of the side walls 56 opposite each other define openings 58 through which the cables 48 extend.

All of the components of the terminal assembly 37 are held within the recess 50, with the exception of the isolation switch 42 which extends through an aperture to the lid 54. An alternative is shown in Fig 5, which is the same as that shown in Fig 4, with the exception that all of the components, including the isolation switch 42 are held within the recess 50. A further difference is that it has a push fit lid 60, instead of a hinged lid. The push-fit lid 60 defines an aperture 62, for providing access to the isolation switch 42.

In each of the versions shown in Figs 4 and 5, an insulating material 64 is provided beneath the battery- management instrumentation 44 to provide insulation from heat from the cells 12 below. Also, a lid lock 66 is provided to lock each of the lids 54, 60 in their respective closed positions.

Referring to Fig 6 there is shown a battery compartment 100 of a vehicle, in which a plurality of the battery arrangements 10 are held. In the embodiment shown in Fig 6, the battery compartment 100 holds 153 of the battery arrangements 10. In the embodiment shown, the battery compartment is lined on all sides and below the battery arrangements by thermal insulation 101. In Figure 6, the battery arrangements 10 in the two left hand columns are shown with their respective lids removed so that the terminal assembly 37 of each battery arrangement 10 can be seen. In the next two columns the battery arrangement 10 are shown with their lids 54 in place.

In the two rows on the left hand side of the battery compartment 100, the arrangement of the cables 48 is shown. In the next two rows, further cables 70 are shown to transmit the electric power from the cables 48 to two bus bars 72. The bus bars 72 transmit the power to other places on the vehicle where it is required.

In the remaining rows of battery arrangements 10, the further cables 72 are omitted for clarity.

The cells 12 used in the battery arrangement are cells commonly used in ZEBRA batteries, which are known in the art. The cells 12 comprise a casing formed of mild steel in which sodium chloride and nickel powder are held, together with a solid electrolyte in the form of a beta- alumina ceramic tube and a liquid secondary electrolyte, sodium tetra-chloro-aluminate. During charging, sodium ion transit the solid electrolyte to leave a coating of nickel chloride on the nickel powder, which provides the positive electrode. The cells have an operating temperature range of at least 250⁰C to 360⁰C, which is above the melting point of sodium tetra-chloride-aluminate . The vacuum insulation within the casing 22 of the battery arrangement means that the casing 22 is only warm to the touch, when an individual battery arrangement is used in ambient temperature surroundings. The vacuum insulation in the space 28 is preferably a material based on titanium oxide and silica. Alternatively, the insulation material could be in the form of compressed calcium silicate powder microporous boards, which may include iron oxide and silicon carbide additives to reduce infra-red transmission.

There is thus described an effective battery arrangement 10 for providing electric power for vehicles such as ships or submarines. The preferred embodiment of the battery arrangement 10 provides the advantages of being lighter than known battery arrangements, provides greater reliability, and higher energy storage density than prior art batteries. Various modifications can be made without departing from the scope of the invention. For example different arrangement of cells could be provided in the battery arrangements .

Claims

1. A battery arrangement (10) comprising: a housing (22); a plurality of electric cells (12) arranged in a plurality of layers (14,16,18,20) within the housing (22), wherein the layers (14,16,18,20) of electric cells (12) define a space (34) extending within the housing (22); a plurality of connection members (36) to connect the cells (12) electrically to one another; and a terminal assembly (37) on the housing (22) to connect the battery arrangement (10) electrically to an article wherein some of the electrical connection members (36) extend through the space (34) from the electric cells (12) to electrically connect the cells (12) to the terminal assembly (37).

2. A battery arrangement (10) according to claim 1 characterised in that the electric cells (12) are arranged in a plurality of layers (14,16,18,20), wherein the layers (14,16,18,20) are arranged one upon the other, the aforesaid space (34) extending vertically through the layers (14,16,18,20).

3. A battery arrangement (10) according to claims 1 or 2 characterised in that the housing (22) comprises inner (24) and outer (26) walls, defining a gap (28) therebetween, the housing (22) further including thermal insulation between the inner (24) and outer (26) walls.

4. A battery arrangement (10) according to claim 3 characterised in that thermal insulation comprises a compressed sintered vacuum material.

5. A battery arrangement (10) according to claim 4 characterised in that the thermal insulation further includes material to reduce infra-red transmission.

6. A battery arrangement (10) according to any preceding claim characterised in that each of the electric cells (12) comprises a salt material and a metal.

7. A battery arrangement (10) according to claim 6 characterised in that the salt is sodium chloride and/or nickel chloride and the metal comprises nickel and/or sodium.

8. A battery arrangement (10) according to any preceding claim characterised in that each of said layers (14,16,18,20) comprises a leakage sump (30) upon which the cells (12) are disposed, the leakage sump (30) comprising an insulation material to thermally insulate each layer (14,16,18,20) from the layer below.

9. A battery arrangement (10) according to claim 8 characterised in that the material in the leakage sump (30) comprises a corrugated material.

10. A battery arrangement (10) according to any preceding claim characterised in that the space (34) comprises a support member (32), through which the connection members (36) extend, the support member (32) providing support for each layer (14,16,18,20) of the electric cells (12).

11. A battery arrangement (10) according to any preceding claim characterised in that heating (31) means is provided on each of the layers (14,16,18,20) to heat the electric cells (12) of the respective layer (14,16,18,20).

12. A battery compartment (100) comprising a plurality of battery arrangements (10) as claimed in any preceding claim.

13. A battery compartment (100) according to claim 12 characterised in that a bus bar arrangement (72) and a plurality of cables (48) connect the battery arrangements

(10) to the bus bar arrangements (72).

14. A battery compartment (100) according to claim 13 characterised in that the bus bar arrangement (72) comprises first and second bus bars extending across the battery arrangements (10).

15. A battery compartment (100) according to claim 14 characterised in that the bus bars (72) extend substantially parallel to each other.

16. A battery compartment (100) as claimed in any of claims 12-15 characterised in that the battery compartment

(100) is lined with thermal insulation (101).

17. A battery compartment (100) as claimed in claim 16 characterised in that the thermal insulation (101) extends from below the battery arrangements (10) up to the height of the battery arrangements (10) .

18. A vehicle incorporating a battery compartment (100) as claimed in any of claims 12 to 17.