Battery cell cooling

Abstract

Cooling system for a rechargeable battery pack, comprising a plurality of heat cooling channels designed to be positioned between adjacent rows of individual battery cells of the battery pack, an inlet flow channel in fluid connection with each of the plurality of heat cooling channels and designed to be connected to a coolant supply and to provide a flow path between the coolant supply and each of the plurality of heat cooling channels, and an outlet flow channel in fluid connection with each of the plurality of heat cooling channels and designed to provide a flow path for coolant to exit from each of the plurality of heat cooling channels, wherein the inlet flow channel includes at least one U-hose connector designed to route the inlet flow channel around a structural transverse element of the battery pack.

Description

Introduction

[0001] The present description relates to a battery cell cooling system within a rechargeable battery pack of an electric vehicle, which has channels designed to provide a supply of cooling fluid to and from heat cooling channels.

[0002] In particular, aspects of this description relate to multifunctional, integrated structural support beams with internal cooling channels and tunable elastic transverse compliance, and further include protection against heat propagation events. Heat propagation refers to a situation in which the temperature of one battery cell rises rapidly, causing the temperature of an adjacent battery cell to also rise rapidly. Rigid crossbeams are used for structural integrity. Separate cooling channels are used to provide a flow of cooling fluid through the battery pack and absorb heat, thereby cooling the battery pack. These individual components occupy space within the battery pack, resulting in a reduction of the overall energy density of the battery pack.

[0003] While current battery packs fulfill their intended purpose, there is therefore a need for a new and improved cooling system for a battery pack with efficient routing of coolant between heat cooling channels within the cooling system. Description

[0004] According to several aspects of the present description, a cooling system for a rechargeable battery pack includes a plurality of heat cooling channels designed to be positioned between adjacent rows of individual battery cells of the battery pack, an inlet flow channel in fluid communication with each of the plurality of heat cooling channels and designed to be connected to a coolant supply and to provide a flow path between the coolant supply and each of the plurality of heat cooling channels, and an outlet flow channel in fluid communication with each of the plurality of heat cooling channels and designed to provide a flow path so that coolant exits from each of the plurality of heat cooling channels, wherein the inlet flow channel includes at least one U-hose connector designed to route the inlet flow channel around a structural transverse element of the battery pack.

[0005] According to a further aspect, the inlet flow channel comprises a plurality of inlet flow channel segments, and wherein a first inlet flow channel segment includes a distal end with a connection base positioned thereon, the connection base of the distal end of the first inlet flow channel having an upwardly directed opening designed to receive a downwardly directed first distal end of the at least one U-hose connector, and a second inlet flow channel segment includes a distal end with a connection base positioned thereon, the connection base of the second inlet flow channel having an upwardly directed opening designed to receive a downwardly directed second distal end of the at least one U-hose connector, and the at least one U-hose connector has a shapeextending upwards from the connection base of the first inlet flow channel segment, laterally across a structural transverse element of the battery pack and downwards to the connection base of the second inlet flow channel segment, defining a flow path that connects the first inlet flow channel segment with the second inlet flow channel segment.

[0006] According to another aspect, the first distal end of the at least one U-hose connector includes a hose attachment mounted thereon, which is designed to be attached to the connection base of the first inlet flow channel segment in order to secure the first distal end of the at least one U-hose connector within the opening of the connection base of the first inlet flow channel segment, and the second distal end of the at least one U-hose connector includes a hose attachment mounted thereon, which is designed to be attached to the connection base of the second inlet flow channel segment in order to secure the second distal end of the at least one U-hose connector within the opening of the connection base of the second inlet flow channel segment.

[0007] According to another aspect, the flow path defined by the at least one U-hose connector has a cross-sectional area that decreases from the first distal end of the at least one U-hose connector to the second distal end of the at least one U-hose connector, while the flow rate of coolant flowing from the first distal end to the second distal end increases.

[0008] According to another aspect, the flow path defined by the at least one U-hose connector includes features that extend into the flow path at a position closer to the second distal end of the at least one U-hose connector than the first distal end of the U-hose connector, wherein the features are designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow.

[0009] According to another aspect, the at least one U-hose connector includes a plurality of small tubes positioned within the flow path parallel to the coolant flow next to the second distal end of the at least one U-hose connector, the tubes being designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow.

[0010] According to another aspect, the flow path defined by the at least one U-hose connector includes an inner surface with a coating designed to reduce friction on the inner surface.

[0011] According to a further aspect, the flow path defined by the at least one U-hose connector includes at least one feature with a cross-sectional area decreasing from the first distal end of the at least one U-hose connector to the second distal end of the at least one U-hose connector, features extending into the flow path at a position closer to the second distal end of the at least one U-hose connector than the first distal end of the U-hose connector, wherein the features are designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow, and a plurality of small tubes positioned therein parallel to the coolant flow within the flow path adjacent to the second distal end of the at least one U-hose connector, wherein the tubes are designed toto reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow, and an inner surface with a coating on it designed to reduce the friction of the inner surface.

[0012] According to another aspect, the outlet flow channel comprises a plurality of outlet flow channel segments and a main outlet channel, and wherein each outlet flow channel segment includes a distal end with a connection base positioned thereon and a vertical connector, the connection base having an upward-facing opening, wherein a downward-facing first distal end of the vertical connector is received within the upward-facing opening of the connection base, the main outlet channel extending laterally across the plurality of heat cooling channels and structural transverse elements of the battery pack and being in fluid communication with second distal ends of the vertical connector of each of the plurality of outlet flow channel segments.and wherein coolant flows from the multitude of heat cooling channels into the multitude of outlet flow channel segments and upwards through the vertical connectors of the multitude of outlet flow channel segments to the main outlet channel.

[0013] According to another aspect, for each of the multitude of outlet flow channel segments, the first distal end of the vertical connector of the outlet flow channel segment includes a hose attachment mounted thereon, which is designed to be attached to the connection base of the outlet flow channel segment in order to secure the first distal end of the vertical connector within the opening of the connection base of the outlet flow channel segment, and the second distal end of the vertical connector defines one of a T-connection or an L-connection to the main outlet channel.

[0014] According to another aspect, for each of the multitude of outlet flow channel segments, the vertical connector defines a flow path from the connection base of the outlet flow channel segment to the main outlet channel, and a cross-sectional area of ​​the flow path of the vertical connector is individually calibrated so that a total pressure drop across the vertical connector between the outlet flow channel segment and the main outlet channel is the same for each of the multitude of outlet flow channel segments.

[0015] According to another aspect, the vertical connector of each of the multiple outlet flow channel segments includes a selectively variable valve, wherein the cross-sectional area of ​​the flow path of the vertical connector is selectively and independently variable.

[0016] According to another aspect, for each of the multitude of outlet flow channel segments, the cross-sectional area of ​​the flow path of the vertical connector is individually calibrated based on an empirical correlation of the cross-sectional area of ​​the vertical connectors for each of the outlet flow channel segments and a distance of the vertical connector from an inlet port and an outlet port, wherein the inlet port is designed to connect the inlet flow channel to an external coolant source, and the outlet port is designed to connect the outlet flow channel to the external coolant source.

[0017] According to another aspect, for each of the multitude of outlet flow channel segments, the vertical connector defines a flow path from the connection base of the outlet flow channel segment to the main outlet channel, wherein the flow path includes turbulator features designed to increase turbulence within the flow of coolant through the flow path, and a density of the turbulator features within the flow path of the vertical connector is individually calibrated so that a pressure drop across the vertical connector between the outlet flow channel segment and the main outlet channel is the same for each of the multitude of outlet flow channel segments.

[0018] According to several aspects of the present description, a rechargeable battery pack comprises a plurality of battery cells and a cooling system for cooling the battery cells, wherein the cooling system comprises a plurality of heat cooling channels designed to be positioned between adjacent rows of individual battery cells of the battery pack, an inlet flow channel in fluid connection with each of the plurality of heat cooling channels and designed to be connected to a coolant supply and to provide a flow path between the coolant supply and each of the plurality of heat cooling channels, and an outlet flow channel in fluid connection with each of the plurality of heat cooling channels and designed to provide a flow path so that coolant exits from each of the plurality of heat cooling channels.wherein the inlet flow channel comprises a plurality of inlet flow channel segments and at least one U-hose connector designed to guide the inlet flow channel around a structural transverse element of the battery pack, wherein a first inlet flow channel segment comprises a distal end with a connection base positioned thereon, wherein the connection base of the distal end of the first inlet flow channel comprises an upwardly directed opening designed to receive a downwardly directed first distal end of the at least one U-hose connector, and the first distal end of the at least one U-hose connector comprises a hose attachment mounted thereon designed to be attached to the connection base of the first inlet flow channel segment,to secure the first distal end of the at least one U-hose connector within the opening of the connection base of the first inlet flow channel segment, and a second inlet flow channel segment includes a distal end with a connection base positioned thereon, the connection base of the second inlet flow channel having an upwardly directed opening designed to receive a downwardly directed second distal end of the at least one U-hose connector, and the second distal end of the at least one U-hose connector including a hose attachment mounted thereon designed to be attached to the connection base of the second inlet flow channel segment in order to secure the second distal end of the at least one U-hose connector within the opening of the connection base of the second inlet flow channel segment, and the at least one U-hose connector having a shapeextending upwards from the connection base of the first inlet flow channel segment, laterally across a structural transverse element of the battery pack and downwards to the connection base of the second inlet flow channel segment, defining a flow path that connects the first inlet flow channel with the second inlet flow channel.

[0019] Further areas of application will become apparent from the description provided herein. It is understood that the description and specific examples serve only as illustrations and are not intended to limit the scope of this description. Brief description of the drawings

[0020] The drawings described herein serve only for illustrative purposes and are not intended to limit the scope of the present description in any way. Fig. Figure 1 is a schematic view of a vehicle with a battery pack and a cooling system according to an exemplary embodiment of the present description; Fig. Figure 2 is a schematic view of a battery pack frame housing for the battery pack and cooling system according to an exemplary embodiment; Fig. Figure 3 is a schematic view of the battery pack frame housing with the cooling system and a multitude of battery cells arranged therein; Fig. Figure 4 is a schematic perspective view of the cooling system according to an exemplary embodiment of the present description; Fig. 5A is an enlarged view of a section of Fig. 4, as described by the one with “ Fig. 5A” designated the circled section of Fig. 4 displayed; Fig. 5B is a schematic view of the in Fig. 5A first U-hose connector shown, wherein the first U-hose connector is shown removed from the cooling system; Fig. 6A is an enlarged view of a section of Fig. 4, as described by the one with “ Fig. 6A” designated the circled section of Fig. 4 displayed; Fig. 6B is a schematic view of the in Fig. 6A second U-hose connector shown, the second U-hose connector shown removed from the cooling system; Fig. Figure 7 is a schematic sectional view of the first and second U-hose connectors, each of the first and second U-hose connectors having a decreasing cross-sectional area; Fig. Figure 8 is a schematic sectional view of the first and second U-hose connectors, each of the first and second U-hose connectors having features that extend into a flow path; Fig. Figure 9 is a schematic sectional view of the first and second U-hose connectors, each of the first and second U-hose connectors incorporating a plurality of tubes positioned within a flow path therein; Fig. Figure 10 is a sectional view of the first and second U-hose connectors along line 10-10 in Fig. 9; Fig. Figure 11 is a schematic sectional view of the first and second U-hose connectors, wherein an inner surface of each of the first and second U-hose connectors has a coating designed to reduce frictional resistance; Fig. Figure 12 is a schematic exploded view of a first distal end of a first, a second and a third vertical connector; Fig. Figure 13 is an enlarged view of a section of Fig. 4, as described by the one with “ Fig. 13” designated circled section of Fig. 4 displayed; Fig. Figure 14A is a sectional view of the flow path of the first vertical connector with a multitude of turbulators in it; Fig. Figure 14B is a sectional view of the flow path of the second vertical connector containing a multitude of turbulators, the density of which is lower than the density of which is found in the first vertical connector; and Fig. Figure 14C is a cross-sectional view of the flow path of the third vertical connector without turbulators in it.

[0021] The figures are not necessarily to scale, and some features may be enlarged or reduced to show, for example, details of certain components. In some cases, well-known components, systems, materials, or processes have not been described in detail to avoid obscuring the present description. Therefore, specific structural and functional details described herein are not to be interpreted as limiting, but merely as a basis for the patent claims and as a representative basis for teaching a person skilled in the art to use the present description in various ways. Detailed description

[0022] The following description is merely exemplary and is not intended to limit the present description, application, or uses. Furthermore, there is no intention to be bound by any theory expressed or implied in the preceding technical field, background, summary, or detailed description. It is understood that in the drawings, identical reference numerals denote identical or corresponding parts and features. As used herein, the term "module" refers to any hardware, software, firmware, electronic control component, processing logic, and / or processor device, individually or in any combination, including, without limitation, application-specific integrated circuits (AICs).: application-specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or grouped) and memory executing one or more software or firmware programs, a combinational logic circuit, and / or other suitable components providing the described functionality. Although the figures shown herein represent an example with specific arrangements of elements, additional intervening elements, devices, features, or components may be present in actual embodiments. It is also understood that the figures are for illustrative purposes only and may not be drawn to scale.

[0023] As used herein, the term "vehicle" is not limited to motor vehicles. Although the technology presented here is primarily described in connection with motor vehicles, it is not limited to motor vehicles. The concepts can be used in a wide variety of applications, such as in connection with aircraft, watercraft, other vehicles, and non-vehicle-related consumer electronics components.

[0024] According to an exemplary embodiment of the present description, Fig. 1. A vehicle 10 with an associated battery pack 50, which includes a cooling system 52 as described herein. Generally, the battery pack 50 operates in conjunction with other systems within the vehicle 10 to provide power to one or both of an electric drive system 20 within the vehicle 10 and / or the various systems within the vehicle 10. The vehicle 10 generally comprises a chassis 12, a body 14, front wheels 16, and rear wheels 18. The body 14 is mounted on the chassis 12 and essentially encloses components of the vehicle 10. The body 14 and the chassis 12 may together form a frame. The front wheels 16 and rear wheels 18 are each rotatably coupled to the chassis 12 near their respective corners.

[0025] In various embodiments, the vehicle 10 is an autonomous vehicle. For example, an autonomous vehicle 10 is one that is automatically controlled to transport passengers from one place to another. In the illustrated embodiment, the vehicle 10 is depicted as a passenger car; however, it is understood that any other vehicle, including motorcycles, trucks, SUVs, recreational vehicles (RVs), etc., can also be used. In one exemplary embodiment, the vehicle 10 is equipped with a so-called Level Four or Level Five automation system. A Level Four system indicates "high automation" and refers to the driving-mode-specific performance of all aspects of the dynamic driving task by an automated driving system, even if a human driver does not respond appropriately to a request for intervention.A Level Five system indicates "full automation" and refers to the full-time performance of all aspects of the dynamic driving task by an automated driving system under all road and environmental conditions that can be handled by a human driver. The novel aspects of this description are also applicable to non-autonomous vehicles.

[0026] As shown, the vehicle 10 generally includes an electric drive system 20, a transmission system 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one data storage device 32, a vehicle control unit 34, and a wireless communication module 36. In an embodiment in which the vehicle 10 is an electric vehicle, the electric drive system may include one or more electric motors connected to and powered by the battery pack 50, and there may be no transmission system 22. The transmission system 22 is configured to transmit power from the drive system 20 to the front wheels 16 and rear wheels 18 of the vehicle according to selectable speed ratios. According to various embodiments, the transmission system 22 may include a multi-speed automatic transmission, a continuously variable transmission, or another suitable transmission.The braking system 26 is configured to provide a braking torque to the front wheels 16 and rear wheels 18 of the vehicle. The braking system 26 may, in various embodiments, include friction brakes, brake-by-wire, a regenerative braking system such as an electric motor, and / or other suitable braking systems. The steering system 24 influences the position of the front wheels 16 and rear wheels 18. Although shown for illustrative purposes as including a steering wheel, the steering system 24 may not include a steering wheel in some embodiments considered within the scope of this description, such as for a fully autonomous vehicle.

[0027] The sensor system 28 includes one or more sensing devices 40a-40n that detect observable conditions of the external environment and / or the internal environment of the vehicle 10. The sensing devices 40a-40n may include, among others, radar, lidar, global positioning systems, optical cameras, thermal cameras, ultrasonic sensors, and / or other sensors. In an exemplary embodiment, the plurality of sensing devices 40a-40n includes at least one of an engine speed sensor, an engine torque sensor, an electric drive motor voltage and / or current sensor, an accelerator pedal position sensor, a coolant temperature sensor, a cooling fan speed sensor, and a transmission oil temperature sensor.The actuator system 30 includes one or more actuator devices 42a-42n that control one or more features of the vehicle 10, such as, among others, the drive system 20, the transmission system 22, the steering system 24 and the braking system 26.

[0028] The vehicle control unit 34 includes at least one processor 44 and a computer-readable storage device or computer-readable storage medium 46. The at least one data processor 44 can be any custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors assigned to the vehicle control unit 34, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, any combination thereof, or generally any device for executing instructions. The computer-readable storage device or computer-readable storage medium 46 can, for example, include volatile and non-volatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM).KAM is a persistent or non-volatile memory that can be used to store various operating variables while at least one data processor 44 is switched off. The computer-readable storage device or computer-readable storage medium 46 can be implemented using any of a number of known storage devices such as PROMs (programmable read-only memory), EPROMs (electrical PROMs), EEPROMs (electrically erasable PROMs), flash memory, or any other electrical, magnetic, optical, or combined storage devices capable of storing data, some of which represent executable instructions used by the controller 34 in controlling the vehicle 10.

[0029] The instructions can include one or more separate programs, each containing an ordered list of executable instructions for implementing logical functions. When executed by the at least one processor 44, the instructions receive and process signals from the sensor system 28, perform logic, calculations, procedures, and / or algorithms to automatically control the components of the vehicle 10, and generate control signals to the actuator system 30 to automatically control the components of the vehicle 10 based on the logic, calculations, procedures, and / or algorithms. Although in Fig. 1 where only one controller 34 is shown, embodiments of the vehicle 10 may include any number of controllers 34 which communicate via any suitable communication medium or combination of communication media and which work together to process the sensor signals, perform logic, calculations, procedures and / or algorithms and generate control signals to automatically control features of the vehicle 10.

[0030] The wireless communication module 36 is configured to wirelessly communicate information to and from other remote entities 48, such as, but not limited to, other vehicles (“V2V” communication), infrastructure (“V2I” communication), remote systems, remote servers, cloud computers, and / or personal devices. In one exemplary embodiment, the communication system 36 is a wireless communication system configured to communicate over a wireless local area network (WLAN) using IEEE 802.11 standards or using cellular data communication. However, additional or alternative communication methods, such as a dedicated short-range communications (DSRC) channel, are also considered within the scope of this description.DSRC channels refer to one-way or two-way short-range to medium-range wireless communication channels specifically designed for automotive use and a corresponding set of protocols and standards.

[0031] The vehicle control unit 34 is a non-generalised electronic control device comprising a pre-programmed digital computer or processor, memory or non-volatile computer-readable medium used for storing data such as control logic, software applications, instructions, computer code, data, lookup tables, etc., and a transceiver [or input / output connectors]. A computer-readable medium includes any type of medium accessible by a computer, such as read-only memory (ROM), random-access memory (RAM), a hard disk drive, a compact disc (CD), a digital video disc (DVD), or any other type of storage. A "non-volatile" computer-readable medium excludes wired, wireless, optical, or other communication links carrying volatile electrical or other signals.Non-volatile, computer-readable media includes media in which data can be permanently stored and media in which data can be stored and later overwritten, such as a rewritable optical disc or an erasable storage device. Computer code includes any type of program code, including source code, object code, and executable code.

[0032] With reference to Fig. Figure 2 shows a schematic perspective view of an example of a battery pack frame housing 54 for the electric vehicle 10 with five structural cross members 56 extending across the entire width of the battery pack frame housing 54 along an X-direction. Two structural frame housing side members 58 run along the length of the battery pack frame housing 54 in a Y-direction, protecting the battery cells 60 of the battery pack 50. With reference to Fig. 3 The battery pack 50 includes a variety of heat cooling channels 62 or Superbeam assemblies located between adjacent rows of battery cells 60 and oriented perpendicular to the frame housing side supports 58.

[0033] Details of the Superbeam assemblies, referred to herein as heat cooling channels 62, are contained in patent application No. 18 / 499,726 entitled “Multi-Function Beam with Integrated Structural, Cooling, and Transverse Elastic Compliance Functions For Use with Electric Vehicle Battery Packs” and have an application date of 1 November 2023, the entirety of which is hereby incorporated into the present application by reference.

[0034] With reference to Fig. Figure 4 shows the cooling system 52, with the rows of battery cells 60 spaced between the plurality of heat cooling channels 62. The cooling system 52 includes an inlet flow channel 64 in fluid communication with each of the plurality of heat cooling channels 62 and has a first distal end 80A with an inlet port 66 designed to be connected to a coolant supply 68 and to provide a flow path between the coolant supply 68 and each of the plurality of heat cooling channels 62, as indicated by arrow 70. The cooling system 52 further includes an outlet flow channel 72 in fluid communication with each of the plurality of heat cooling channels 62 and designed to provide a flow path for coolant to exit each of the plurality of heat cooling channels 62 and return to the coolant supply 68, as indicated by arrow 74.

[0035] The battery pack 50 and the cooling system 52 are divided into modules, each module consisting of a section of the plurality of heat cooling channels 62 and a section of the battery cells 60 positioned between them, which are located between adjacent structural crossbeams 56. As shown in Fig. As shown in Figure 4, the cooling system 52 includes a first module 76A next to a first structural crossbeam 56A, a second module 76B between the first structural crossbeam 56A and a second structural crossbeam 56B, and a third module 76C between the second structural crossbeam 56B and a third structural crossbeam 56C. The Fig. The exemplary cooling system 52 shown in Figure 4 serves for illustration. It is understood by those skilled in the art that the battery pack 50 and the cooling system 52 can include any suitable number of structural cross members 56 and corresponding modules. In order for the inlet flow channel 64 to extend over the structural cross members 56A, 56B, 56C without having to form a passage through them, the inlet flow channel 64 includes at least one U-shaped hose connector 78A, 78B, which is designed to guide the inlet flow channel 64 around a structural cross member 56 of the battery pack 50.

[0036] In an exemplary embodiment, the inlet flow channel 64 comprises a plurality of inlet flow channel segments 64A, 64B, 64C. A first U-hose connector 78A connects a first inlet flow channel segment 64A and a second inlet flow channel segment 64B, and a second U-hose connector 78B connects the second inlet flow channel segment 64B to a third inlet flow channel segment 64C.

[0037] The connection of the first inlet flow channel segment 64A with the second inlet flow channel segment 64B with the first U-hose connector 78A is essentially identical to the connection of the second inlet flow channel segment 64B with the third inlet flow channel segment 64C with the second U-hose connector 78B.

[0038] With reference to Fig. 5A and Fig. The first inlet flow channel segment 64A includes a second distal end 80B with a connection base 82A positioned thereon. The connection base 82A of the second distal end 80B of the first inlet flow channel 64A includes an upwardly directed opening 84A designed to receive a downwardly directed first distal end 86A of the first U-hose connector 78A. The second inlet flow channel segment 64B includes a first distal end 88A with a connection base 82B positioned thereon, wherein the connection base 82B of the second inlet flow channel segment 64B includes an upwardly directed opening 84B designed to receive a downwardly directed second distal end 86B of the first U-hose connector 78A.The first distal end 86A of the first U-hose connector 78A and the second distal end 86B of the first U-hose connector 78A each include an O-ring 90 designed to create a fluid seal between the first U-hose connector 78A and the connection bases 82A, 82B.

[0039] Furthermore, the first distal end 86A of the first U-hose connector 78A includes a hose attachment 92 mounted thereon, which is designed to be attached to the connection base 82A of the first inlet flow channel segment 64A in order to secure the first distal end 86A of the first U-hose connector 78A within the opening 84A of the connection base 82A of the first inlet flow channel segment 64A, and the second distal end 86B of the first U-hose connector 78A includes a hose attachment 92 mounted thereon, which is designed to be attached to the connection base 82B of the first distal end 88A of the second inlet flow channel segment 64B in order to secure the second distal end 86B of the first U-hose connector 78A within the opening 84B of the connection base 82B of the second inlet flow channel segment 64B.In an exemplary embodiment, the hose fittings 92 are attached to the connection bases 82A, 82B by means of a threaded fastening element (not shown).

[0040] The first U-hose connector 78A has a shape extending upwards from the connection base 82A of the first inlet flow channel segment 64A, as indicated by arrow 94, laterally over the first structural transverse element 56A of the battery pack 50, as indicated by arrow 96, and downwards to the connection base 82B of the second inlet flow channel segment 64B, as indicated by arrow 98, defining a flow path 100 that connects the first inlet flow channel segment 64A with the second inlet flow channel segment 64B.

[0041] With reference to Fig. 6A and Fig. The second inlet flow channel segment 64B includes a second distal end 88B with a connection base 82C positioned thereon. The connection base 82C of the second distal end 88B of the second inlet flow channel 64B includes an upwardly directed opening 84C designed to receive a downwardly directed first distal end 86C of the second U-hose connector 78B. The third inlet flow channel segment 64C includes a first distal end 102A with a connection base 82D positioned thereon. The connection base 82D of the first distal end 102A of the third inlet flow channel segment 64C includes an upwardly directed opening 84D designed to receive a downwardly directed second distal end 86D of the second U-hose connector 78B.The first distal end 86C of the second U-hose connector 78B and the second distal end 86D of the second U-hose connector 78B each include an O-ring 90 designed to create a fluid seal between the second U-hose connector 78B and the connection bases 82C, 82D.

[0042] Furthermore, the first distal end 86C of the second U-hose connector 78B includes a hose clamp 92 mounted thereon, which is designed to be attached to the connection base 82C of the second distal end 88B of the second inlet flow channel segment 64B in order to secure the first distal end 86C of the second U-hose connector 78B within the opening 84C of the connection base 82C of the second distal end 88B of the second inlet flow channel segment 64B; and the second distal end 86D of the second U-hose connector 78B includes a hose clamp 92 mounted thereon, which is designed to be attached to the connection base 82D at the first distal end 102A of the third inlet flow channel segment 64C in order to secure the second distal end 86D of the second U-hose connector 78B within the opening 84D of the connection base. 82D of the first distal end 102A of the third inlet flow channel segment 64C to be attached.In an exemplary embodiment, the hose fittings 92 are attached to the connection bases 82C, 82D by means of a threaded fastening element (not shown).

[0043] The second U-hose connector 78B has a shape extending upwards from the connection base 82C at the second distal end 88B of the second inlet flow channel segment 64B, as indicated by arrow 104, laterally over the second structural transverse element 56B of the battery pack 50, as indicated by arrow 106, and downwards to the connection base 82D at the first distal end 102A of the third inlet flow channel segment 64C, as indicated by arrow 108, defining a flow path 110 that connects the second inlet flow channel segment 64B with the third inlet flow channel segment 64C.

[0044] With reference to Fig. In an exemplary embodiment, the flow path 100, 110 defined by the first and second U-hose connectors 78A, 78B has a cross-sectional area that decreases from the first distal ends 86A, 86C of the first and second U-hose connectors 78A, 78B to the second distal ends 86B, 86D of the first and second U-hose connectors 78A, 78B, while the flow rate of coolant flowing from the first distal ends 86A, 86C to the second distal ends 86B, 86D within each of the first and second U-hose connectors 78A, 78B increases. The frictional resistance within the flow paths 100, 110 can cause air bubbles 114 to be trapped within the flow paths 100, 110 within the first and second U-hose connectors 78A, 78B.The buoyancy of the air bubbles 114 also acts to resist downward movement of the air bubbles towards the second distal ends 86B, 86D of the first and second U-hose connectors 78A, 78B. By reducing the cross-sectional area of ​​the flow paths 100, 110, the velocity of the coolant flowing therein increases and draws trapped air bubbles 114 through the first and second U-hose connectors 78A, 78B. As in . Fig. As shown in Figure 7, the cross-sectional area 150 of the flow path 100, 110 of each of the first and second U-hose connectors 78A, 78B near the first distal ends 86A, 86C is larger than the cross-sectional area 152 of the flow path 100, 110 of each of the first and second U-hose connectors 78A, 78B near the second distal ends 86B, 86D, and thus the velocity of the coolant entering the first distal ends 86A, 86C of the first and second U-hose connectors 78A, 78B, as indicated by arrow 154, is slower than the velocity of the coolant flowing within the flow paths 100, 110 near the second distal ends 86B, 86D, as indicated by arrow 156.

[0045] With reference to Fig. In another exemplary embodiment, the flow path 100, 110 defined by the first and second U-hose connectors 78A, 78B has features 112 which extend into the flow path 100, 110 at a position closer to the second distal ends 86B, 86D of the first and second U-hose connectors 78A, 78B than the first distal ends 86A, 86C of the first and second U-hose connectors 78A, 78B. The features are positioned on the downward flow side of the first and second U-hose connectors 78A, 78B and extend into the flow path 100, 110 to cause turbulence within the coolant flow, thereby breaking up large air bubbles 114A within the coolant flow, making it easier for the coolant flow to flush the smaller air bubbles 114B through the first and second U-hose connectors 78A, 78B.Furthermore, the features 112 reduce the cross-sectional area of ​​the flow paths 100, 110, thereby increasing the velocity of the coolant flow through the flow paths 100, 110 and allowing the smaller air bubbles 114B trapped therein to be drawn more efficiently through the first and second U-hose connectors 78A, 78B. The features 112 can be bumps or finger-like extensions extending into the flow paths 100, 110, or they can be annular rings or ribs extending around an inner diameter of the first and second U-hose connectors 78A, 78B.

[0046] With reference to Fig. 9 and Fig. Each of the first and second U-hose connectors 78A, 78B includes a plurality of small tubes 116 positioned within the flow path 100, 110 parallel to the coolant flow and adjacent to the second distal ends 86B, 86D of the first and second U-hose connectors 78A, 78B. The tubes 116 are positioned on the downward-facing flow side of the first and second U-hose connectors 78A, 78B and cause turbulence within the coolant flow, breaking up large air bubbles 114A within the coolant flow. This makes it easier for the coolant flow to flush the smaller air bubbles 114B through the tubes 116 and through the first and second U-hose connectors 78A, 78B.Furthermore, the tubes 116 reduce the cross-sectional area of ​​the flow paths 100, 110, thereby increasing the velocity of the coolant flow through the flow paths 100, 110 and allowing the smaller air bubbles 114B trapped therein to be drawn more efficiently through the first and second U-hose connectors 78A, 78B. As shown, the plurality of tubes 116 comprises seven tubes 116 stacked within the flow paths 100, 110 of the first and second U-hose connectors 78A, 78B. It is understood that the plurality of tubes 116 could include a higher number of tubes 116 of an even smaller size. Furthermore, the plurality of tubes 116 could include tubes of different sizes.

[0047] In yet another exemplary embodiment, with reference to Fig. 11, each of the first and second U-hose connectors 78A, 78B includes an inner surface 118 with a coating designed to reduce the friction of the inner surface 118. Reduced friction of the inner surface 118 of the first and second U-hose connectors 78A, 78B decreases the amount of frictional resistance of air bubbles 114 flowing over the inner surface 118. The reduced frictional resistance decreases the contact angle 120° between the bubbles and the inner surface 118 of the first and second U-hose connectors 78A, 78B, making it easier for the coolant flow through the flow paths 100, 110 to flush the air bubbles 114 through the first and second U-hose connectors 78A, 78B.

[0048] It should be understood by a person skilled in the art that the cooling system 52 of the present description can be implemented with one or more or any combination of decreasing cross-sectional area of ​​the flow path 100, 110 within each of the first and second U-hose connectors 78A, 78B, features 112 extending into the flow path 100, 110 defined by each of the first and second U-hose connectors 78A, 78B, a plurality of small tubes 116 positioned within the flow path 100, 110 of each of the first and second U-hose connectors 78A, 78B, and a coating designed to reduce the friction of the inner surface 118 of each of the first and second U-hose connectors 78A, 78B.

[0049] In an exemplary embodiment, the outlet flow channel 72 comprises a plurality of outlet flow channel segments 72A, 72B, 72C and a main outlet channel 72D. A first outlet flow channel segment 72A is in fluid communication with the heat cooling channels 62 of the first module 76A, a second outlet flow channel segment 72B is in fluid communication with the heat cooling channels 62 of the second module 76B, and a third outlet flow channel segment 72C is in fluid communication with the heat cooling channels 62 of the third module 76C. A first vertical connector 122A connects the first exhaust flow channel segment 72A and the main exhaust channel 72D, a second vertical connector 122B connects the second exhaust flow channel segment 72B to the main exhaust channel 72D, and a third vertical connector 122C connects the third exhaust flow channel segment 72C to the main exhaust channel 72D.

[0050] The main outlet channel 72D extends laterally across the multitude of heat-cooling channels 62 and structural transverse elements 56A, 56B, 56C of the battery pack 50. Coolant flows from the multitude of heat-cooling channels 62 within the first module 76A into the first outlet flow channel segment 72A and through the first vertical connector 122A to the main outlet channel 72D and back to the coolant source 68. Coolant flows from the multitude of heat-cooling channels 62 within the second module 76B into the second outlet flow channel segment 72B and through the second vertical connector 122B to the main outlet channel 72D and back to the coolant source 68. Coolant flows from the multitude of heat-cooling channels 62 within the third module 76C into the second outlet flow channel segment 72C and through the third vertical connector 122C to the main outlet channel 72D and back to the coolant source 68. back to coolant source 68.

[0051] With reference to Fig. 5A and Fig. The first outlet flow channel segment 72A includes a distal end 124A with a connection base 126A positioned thereon and comprising an upwardly directed opening 128A, wherein a downwardly directed first distal end 130A of the first vertical connector is received within the upwardly directed opening 128A of the connection base 126A at the distal end 124A of the first outlet flow channel segment 72A. The first distal end 130A of the first vertical connector 122A includes an O-ring 90 designed to create a fluid seal between the first vertical connector 122A and the connection base 126A at the distal end 124A of the first outlet flow channel segment 72A.

[0052] Furthermore, the first distal end 130A of the first vertical connector 122A includes a hose clamp 92 mounted thereon, which is designed to be attached to the connection base 126A of the distal end 124A of the first outlet flow channel segment 72A in order to secure the first distal end 130A of the first vertical connector 122A within the opening 128A of the connection base 126A at the distal end 124A of the first outlet flow channel segment 72A. In an exemplary embodiment, the hose clamp 92 is attached to the connection base 126A by a threaded fastening element (not shown).

[0053] With reference to Fig. 6A and Fig. The second outlet flow channel segment 72B includes a distal end 124B with a connecting base 126B positioned thereon and comprising an upwardly directed opening 128B, wherein a downwardly directed first distal end 132A of the second vertical connector 122B is received within the upwardly directed opening 128B of the connecting base 126B at the distal end 124B of the second outlet flow channel segment 72B. The first distal end 132A of the second vertical connector 122B includes an O-ring 90 designed to create a fluid seal between the second vertical connector 122B and the connecting base 126B at the distal end 124B of the second outlet flow channel segment 72B.

[0054] Furthermore, the first distal end 132A of the second vertical connector 122B includes a hose clamp 92 mounted thereon, which is designed to be attached to the connection base 126B of the distal end 124B of the second outlet flow channel segment 72B in order to secure the first distal end 132A of the second vertical connector 122B within the opening 128B of the connection base 126B at the distal end 124B of the second outlet flow channel segment 72B. In an exemplary embodiment, the hose clamp 92 is attached to the connection base 126B by a threaded fastening element (not shown).

[0055] With reference to Fig. 12 and Fig. 13 The third outlet flow channel segment 72C includes a distal end 124C with a connecting base 126C positioned thereon and comprising an upwardly directed opening 128C, wherein a downwardly directed first distal end 134A of the third vertical connector 122C is received within the upwardly directed opening 128C of the connecting base 126C at the distal end 124C of the third outlet flow channel segment 72C. The first distal end 134A of the third vertical connector 122C includes an O-ring 90 designed to create a fluid seal between the third vertical connector 122C and the connecting base 126C at the distal end 124C of the third outlet flow channel segment 72C.

[0056] Furthermore, the first distal end 134A of the third vertical connector 122C includes a hose clamp 92 mounted thereon, which is designed to be attached to the connection base 126C of the distal end 124C of the third outlet flow channel segment 72C in order to secure the first distal end 134A of the third vertical connector 122C within the opening 128C of the connection base 126C at the distal end 124C of the third outlet flow channel segment 72C. In an exemplary embodiment, the hose clamp 92 is attached to the connection base 126C by a threaded fastening element (not shown).

[0057] With renewed reference to Fig. 5A A second distal end 130B of the first vertical connector 122A is in fluid communication with the main outlet channel 72D via a T-connection, with coolant flowing through the second distal end 130B of the first vertical connector 122A from the first outlet flow channel segment 72A, as indicated by arrow 136, and from the second and third outlet flow channels 122B, 122C, as indicated by arrow 138. With further reference to Fig. 6A A second distal end 132B of the second vertical connector 122B is in fluid communication with the main outlet channel 72D via a T-connection, with coolant flowing through the second distal end 132B of the second vertical connector 122B from the second outlet flow channel segment 72B, as indicated by arrow 140, and from the third outlet flow channel 122C, as indicated by arrow 142. With further reference to Fig. 13 A second distal end 134B of the third vertical connector 122C is in fluid communication with the main outlet channel 72D via an L-connection, with coolant flowing through the second distal end 134B of the third vertical connector 122C from the third outlet flow channel segment 72C, as indicated by arrow 144.

[0058] In an exemplary embodiment, with further reference to Fig. 12, defines for each of the first, second and third outlet flow channels 72A, 72B, 72C the vertical connector 122A, 122B, 122C a flow path 144 from the connection base 126A, 126B, 126C of the outlet flow channel segment 72A, 72B, 72C to the main outlet channel 72D, and a cross-sectional area of ​​the flow path 144 of the vertical connector 122A, 122B, 122C is individually calibrated such that a pressure drop across each vertical connector 122A, 122B, 122C between the outlet flow channel segment 72A, 72B, 72C and the main outlet channel 72D is the same. This ensures a balanced flow of coolant through each module 76A, 76B, 76C of the cooling system 52 and uniform cooling of the battery pack 50.

[0059] In an exemplary embodiment, the vertical connector 122A, 122B, 122C includes a selectively variable valve 146 for each of the plurality of outlet flow channel segments 72A, 72B, 72C, wherein the cross-sectional area (effective diameter of a circular flow path) of the flow path 144 of the vertical connector 122A, 122B, 122C is selectively and independently variable. In the simplest sense, the cross-sectional area of ​​the flow path of the first vertical connector 122A is smaller than the cross-sectional area of ​​the flow path of the second vertical connector 122B, which is smaller than the cross-sectional area of ​​the flow path of the third vertical connector 122C, due to the respective distances of each of the first, second, and third vertical connectors 122A, 122B, 122C from the inlet port 66.The selectively variable valve 146 within each vertical connector 122A, 122B, 122C enables the cooling system 52 to maintain a balanced flow from all modules 76A, 76B, 76C under variable conditions.

[0060] In another exemplary embodiment, for each of the first, second and third outlet flow channel segment 72A, 72B, 72C, a fixed cross-sectional area of ​​the flow path of the vertical connector 122A, 122B, 122C is individually calibrated based on an empirical correlation of the cross-sectional area of ​​the vertical connectors 122A, 122B, 122C and a distance of the vertical connector 122A, 122B, 122C from the inlet port 66. In an exemplary embodiment, the Darcy-Weisbach equation can be used to design the first, second and third vertical connectors 122A, 122B, 122C taking into account aspects of the cooling system 52, such as the density of the coolant, volumetric flow rates and the respective distances of each of the first, second and third vertical connectors 122A, 122B, 122C from the inlet port 66.

[0061] In another exemplary embodiment, for each of the first, second, and third outlet flow channel segments 72A, 72B, 72C, the vertical connector 122A, 122B, 122C defines a flow path from the connection base 126A, 126B, 126C of the outlet flow channel segment 72A, 72B, 72C to the main outlet channel 72D, wherein the flow path includes turbulator features 148 designed to increase turbulence within the coolant flow through the flow path. A density of the turbulator features 148 within the flow path of the vertical connector 122A, 122B, 122C is individually calibrated such that a pressure drop across each of the vertical connectors 122A, 122B, 122C varies to compensate for the coolant flow.

[0062] For example, as discussed above, in the simplest sense, the cross-sectional area of ​​the flow path of the first vertical connector 122A is smaller than the cross-sectional area of ​​the flow path of the second vertical connector 122B, which is smaller than the cross-sectional area of ​​the flow path of the third vertical connector 122C, due to the respective distances of each of the first, second, and third vertical connectors 122A, 122B, and 122C from the inlet port 66. The flow of coolant through the first vertical connector 122A must be more restricted than the flow of coolant through the second vertical connector 122B, since the first vertical connector 122A is located closer to the inlet port 66. The flow of coolant through the second vertical connector 122B must be more “throttled” than the flow of coolant through the third vertical connector 122C, because the second vertical connector 122A is closer to the inlet port 66.For example, the first vertical connector incorporates a higher density of turbulator features 148, as in . Fig. 14A is shown as the second vertical connector, as in Fig. 14B shown. Accordingly, the second vertical connector includes, as in Fig. Figure 14B shows a higher density of turbulator features 148 than the third vertical connector 122C, as shown in Figure 14B. Fig. Figure 14C is shown. As shown, the third vertical connector 122C incorporates very few or no turbulator features 148 because its distance from the inlet port 66 is the longest. The second and first vertical connectors 122B, 122A incorporate a calibrated density of turbulator features 148 to ensure that the pressure drop across each of the first, second, and third vertical connectors 122A, 122B, 122C is the same.

[0063] The description provided here is merely exemplary, and variations that do not deviate from the core of the description are to be considered within its scope. Such variations should not be regarded as a departure from the spirit and scope of the description provided. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 18 / 499,726

[0033]

Claims

[1] Cooling system for a rechargeable battery pack, comprising: a multitude of heat cooling channels designed to be positioned between adjacent rows of individual battery cells of the battery pack; an inlet flow channel in fluid connection with each of the multiple heat cooling channels and designed to be connected to a coolant supply and to provide a flow path between the coolant supply and each of the multiple heat cooling channels; and an outlet flow channel in fluid connection with each of the multitude of heat cooling channels and designed to provide a flow path so that coolant exits from each of the multitude of heat cooling channels; wherein the inlet flow channel includes at least one U-shaped hose connector designed to guide the inlet flow channel around a structural transverse element of the battery pack. [2] Cooling system according to claim 1, wherein the inlet flow channel comprises a plurality of inlet flow channel segments, and wherein: a first inlet flow channel segment comprising a distal end with a connecting base positioned thereon, wherein the connecting base of the distal end of the first inlet flow channel comprising an upwardly directed opening designed to to accommodate a downward-facing first distal end of at least one U-shaped hose connector; and a second inlet flow channel segment comprising a distal end with a connection base positioned thereon, the connection base of the second inlet flow channel comprising an upwardly directed opening designed to receive a downwardly directed second distal end of the at least one U-hose connector; and wherein the at least one U-shaped hose connector has a shape extending upwards from the connection base of the first inlet flow channel segment, laterally across a structural transverse element of the battery pack and downwards to the connection base of the second inlet flow channel segment, defining a flow path connecting the first inlet flow channel segment to the second inlet flow channel segment. [3] Cooling system according to claim 2, wherein: the first distal end of the at least one U-hose connector includes a hose fitting mounted thereon, which is designed to be attached to the connection base of the first inlet flow channel segment in order to secure the first distal end of the at least one U-hose connector within the opening of the connection base of the first inlet flow channel segment; and the second distal end of the at least one U-hose connector includes a hose attachment mounted thereon, which is designed to be attached to the connection base of the second inlet flow channel segment in order to secure the second distal end of the at least one U-hose connector within the opening of the connection base of the second inlet flow channel segment. [4] Cooling system according to claim 3, wherein the flow path defined by the at least one U-hose connector has a cross-sectional area that decreases from the first distal end of the at least one U-hose connector to the second distal end of the at least one U-hose connector, wherein a flow rate of coolant flowing from the first distal end to the second distal end increases. [5] Cooling system according to claim 3, wherein the flow path defined by the at least one U-hose connector includes features which extend into the flow path at a position closer to the second distal end of the at least one U-hose connector than the first distal end of the U-hose connector, wherein the features are designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow. [6] Cooling system according to claim 3, wherein the at least one U-hose connector includes a plurality of small tubes positioned within the flow path parallel to the coolant flow within the flow path next to the second distal end of the at least one U-hose connector, wherein the tubes are designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow. [7] Cooling system according to claim 3, wherein the flow path defined by the at least one U-hose connector includes an inner surface with a coating on it designed to reduce the friction of the inner surface. [8] Cooling system according to claim 3, wherein the flow path defined by the at least one U-hose connector includes at least one of the following: a cross-sectional area that decreases from the first distal end of the at least one U-hose connector to the second distal end of the at least one U-hose connector; Features extending into the flow path at a position closer to the second distal end of the at least one U-hose connector than the first distal end of the U-hose connector, wherein the features are designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow; a plurality of small tubes positioned therein parallel to the coolant flow within the flow path next to the second distal end of the at least one U-hose connector, the tubes being designed to reduce the cross-sectional area of ​​the flow path and to break up air bubbles within the coolant flow; and an inner surface with a coating on it designed to reduce the friction of the inner surface. [9] Cooling system according to claim 3, wherein the outlet flow channel comprises a plurality of outlet flow channel segments and a main outlet channel, and wherein: Each outlet flow channel segment includes a distal end with a connection base positioned thereon and a vertical connector, the connection base having an upward-facing opening, wherein a downward-facing first distal end of the vertical connector is received within the upward-facing opening of the connection base; the main outlet channel extends laterally across the multitude of heat cooling channels and structural transverse elements of the battery pack and is in fluid communication with the second distal ends of the vertical connector of each of the multitude of outlet flow channel segments; and where coolant flows from the multitude of heat cooling channels into the multitude of outlet flow channel segments and through the vertical connectors of the multitude of outlet flow channel segments upwards to the main outlet channel. [10] Cooling system according to claim 9, wherein for each of the plurality of outlet flow channel segments: the first distal end of the vertical connector of the outlet flow channel segment includes a hose fitting mounted thereon, which is designed to be attached to the connection base of the outlet flow channel segment in order to secure the first distal end of the vertical connector within the opening of the connection base of the outlet flow channel segment; and the second distal end of the vertical connector is defined as a connection from a T-connection or an L-connection to the main outlet channel.

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