Assembly manifold for thermal runaway exhaust delivery in battery systems
By setting up exhaust systems and sealing materials inside and outside the battery pack, the problem of potting materials is solved, ensuring the sealing and thermal management performance of the exhaust system, and achieving effective gas discharge and temperature reduction.
Patent Information
- Application Number
- CN202311389872.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-06-08
- Filing Date
- 2023-10-24
- Publication Date
- 2024-12-10
AI Technical Summary
In the battery pack system, the closed volume of the thermal runaway exhaust system is easily blocked by the potting material during the manufacturing process, resulting in the inability to effectively discharge the gas, affecting the ventilation and thermal management of the battery pack.
An exhaust system was designed, including the installation of exhaust ports inside and outside the battery pack housing and connected to a manifold through a closed channel network, using sealing materials such as rubber foam and potting materials such as blow-molded foam, composite foam and non- Foam the polymer resin, filling the external voids to prevent the ingress of the potting material, ensure the system is sealed, and communicate with the channel network through the thermal runaway sensor.
It realizes preventing potting materials from entering the exhaust system during the battery pack manufacturing process, ensuring that the gas can be effectively discharged and reduce temperature, and improving the thermal management performance and structural sealing of the battery pack.
Smart Images
Figure CN119108696A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to an assembled manifold for thermal runaway exhaust gas delivery in a battery system. Background Art
[0002] The information provided in this section is for the purpose of generally introducing the background of the present disclosure. No admission is made, either explicitly or implicitly, that the work of the presently named inventors described in this section is prior art to the present disclosure, nor is it admitted that the work is prior art to the present disclosure, as described in this section, which may not otherwise be identified as prior art at the time of filing.
[0003] Ventilation of battery cells of a battery pack of an electric vehicle is known in the art. The exhaust system must remain open for gas to pass through during a thermal event so that the gas can reach the vent port of the battery pack. For electrical isolation, structural performance and thermal insulation, the rest of the battery pack is typically filled with a potting resin (foaming or non-foaming). Controlling the location of the potting is challenging. The variability of foam expansion makes the baseline system incompatible with foam potting. Summary of the invention
[0004] The main purpose of the present disclosure is to create a closed volume for a thermal runaway exhaust system. The closed volume cannot be blocked by potting materials during the manufacturing process.
[0005] According to one aspect of the present disclosure, a battery pack for a vehicle includes a housing including at least one pack vent between an interior and an exterior of the housing. A plurality of battery cells are disposed within the housing. An exhaust system includes a closed channel network below the battery connected to the vents of the plurality of battery cells and the at least one pack vent. A manifold is mounted on the closed channel network, and a portion of the manifold mounted on the housing includes a connector mounted from the exterior into the housing that connects the manifold to the closed channel network.
[0006] According to another aspect, a pack mounted portion of the manifold includes a sealing material that engages the connector.
[0007] According to another aspect, the sealing material comprises rubber foam.
[0008] According to another aspect, the manifold connects passages from at least two modules to a single battery pack vent.
[0009] According to another aspect, potting material fills all voids outside the exhaust system.
[0010] According to another aspect, the potting material includes one of a blown foam, a syntactic foam, and a non-foamed polymer resin.
[0011] According to another aspect, the vent system is sealed to prevent potting material from entering the vent system during battery pack manufacturing.
[0012] According to another aspect, the closed channel network includes an array of battery channels.
[0013] According to another aspect, the battery channel array includes at least two pieces per battery module.
[0014] According to another aspect, the gap between the at least two pieces is less than 3 mm.
[0015] According to another aspect, the closed channel network includes battery trays and vent tray stacks sealed together with other battery trays and vent tray stacks to create a sealed vent channel battery pack module.
[0016] According to another aspect, the sealing may be achieved using at least one of mechanical bonding, fusion bonding, welding, solvent bonding, and adhesive bonding.
[0017] According to another aspect, an end of the battery tray facing the other battery tray contains molded features to achieve one of a snap fit and a press fit.
[0018] According to another aspect, one of the exhaust tray and the battery tray includes a plurality of ribs to define a channel therebetween.
[0019] According to another aspect, a thermal runaway sensor is in communication with the network of channels.
[0020] According to another aspect, a thermal runaway sensor is mounted in the manifold.
[0021] According to a further aspect, a battery pack for a vehicle includes a housing including at least one pack vent between an interior and an exterior of the housing. A plurality of battery cells are disposed within the housing. An exhaust system includes a closed channel network connected to the vents of the plurality of battery cells and the at least one pack vent below the battery. The closed channel network includes battery trays and exhaust tray stacks sealed together with other battery trays and exhaust tray stacks to create a sealed exhaust channel battery module. A manifold is mounted on the closed channel network and includes a connector mounted from the outside into the housing, which connects the manifold to a battery exhaust manifold mounted on a battery tray of the closed channel network.
[0022] The present invention relates to the following scheme:
[0023] Solution 1. A battery pack for a vehicle, comprising:
[0024] a housing including at least one pack vent between an interior and an exterior of the housing;
[0025] a plurality of battery cells disposed within the housing; and
[0026] a vent system comprising a network of enclosed channels beneath the battery connected to the vents of the plurality of battery cells and the at least one battery pack vent; and
[0027] A manifold is mounted on the closed channel network, and a portion of the manifold mounted on the housing includes a connector mounted externally into the housing that connects the manifold to the closed channel network.
[0028] Aspect 2. The battery pack for a vehicle according to aspect 1, wherein a pack mounted portion of the manifold includes a sealing material that engages the connector.
[0029] Option 3. The battery pack for a vehicle according to Option 2, wherein the sealing material comprises rubber foam.
[0030] Option 4. A battery pack for a vehicle according to Option 1, wherein the manifold connects channels from at least two modules to a single battery pack exhaust port.
[0031] Option 5. The battery pack for a vehicle according to Option 1, further comprising a potting material that fills all gaps outside the exhaust system.
[0032] Option 6. The battery pack for a vehicle according to Option 5, wherein the potting material comprises one of a blown foam, a syntactic foam, and a non-foamed polymer resin.
[0033] Option 7. The battery pack for a vehicle according to Option 1, wherein the exhaust system is sufficiently sealed to prevent potting materials from entering the exhaust system during the battery pack manufacturing process.
[0034] Option 8. A battery pack for a vehicle according to Option 1, wherein the closed channel network includes a battery channel array.
[0035] Option 9. A battery pack for a vehicle according to Option 8, wherein the battery channel array includes at least two pieces per battery module.
[0036] Embodiment 10. The battery pack for a vehicle according to Embodiment 9, wherein a gap between the at least two pieces is less than 3 mm.
[0037] Embodiment 11. A battery pack for a vehicle according to embodiment 1, wherein the closed channel network includes battery trays and vent tray stacks sealed together with other battery trays and vent tray stacks to create a sealed vent channel battery pack module.
[0038] Option 12. The battery pack for a vehicle according to Option 11, wherein the sealing can be achieved using at least one of mechanical connection, fusion bonding, welding, solvent bonding and adhesive bonding.
[0039] Option 13. The battery pack for a vehicle according to Option 11, wherein an end of the battery tray facing the other battery tray contains molded features to achieve one of a snap fit and a press fit.
[0040] Aspect 14. The battery pack for a vehicle according to aspect 11, wherein one of the exhaust tray and the battery tray includes a plurality of ribs to define a channel therebetween.
[0041] Embodiment 15. The battery pack for a vehicle according to Embodiment 1, further comprising a thermal runaway sensor in communication with the channel network.
[0042] Option 16. The battery pack for a vehicle according to Option 15, wherein the thermal runaway sensor is installed in the manifold.
[0043] Solution 17. A battery pack for a vehicle, comprising:
[0044] a housing including at least one pack vent between an interior and an exterior of the housing;
[0045] a plurality of battery cells disposed within the housing; and
[0046] a vent system comprising a network of enclosed channels beneath the battery connected to the vents of the plurality of battery cells and the at least one battery pack vent, the network of enclosed channels comprising battery trays and vent tray stacks sealed together with other battery trays and vent tray stacks to create a sealed vent channel battery module; and
[0047] A manifold mounted on the closed channel network, a portion of the manifold mounted on the housing includes a connector mounted from the outside into the housing, which connects the manifold to a battery exhaust manifold mounted on a battery tray of the closed channel network.
[0048] Option 18. The battery pack for a vehicle according to Option 17, wherein one of the connector and the battery exhaust manifold includes a sealing material to join the other of the connector and the battery exhaust manifold.
[0049] Option 19. The battery pack for a vehicle according to Option 18, wherein the sealing material comprises rubber foam.
[0050] Embodiment 20. The battery pack for a vehicle according to Embodiment 17, further comprising a potting material that fills all gaps outside the exhaust system.
[0051] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The present disclosure will be more fully understood from the detailed description and accompanying drawings, in which:
[0053] Figure 1 is a partial cross-sectional view of a battery pack having a vent system according to the principles of the present disclosure;
[0054] Figure 2 is a perspective view of a battery pack vent system having an array of channels connecting individual battery cells to a battery pack vent;
[0055] Figure 3 is a detailed view of the connection between the channel array and the battery pack exhaust manifold;
[0056] Figure 4 is a perspective cutaway view of the connection between the channel array and the battery pack exhaust manifold;
[0057] Figure 5 is a cross-sectional view of a battery tray of a channel array;
[0058] Figure 6 is a cross-sectional view of the interface between adjacent battery trays;
[0059] Figure 7 is an exemplary schematic diagram of a channel array system; and
[0060] Figure 8 is a cross-sectional view of the battery pack exhaust manifold.
[0061] In the drawings, reference numerals may be repeated to designate similar and / or identical elements. DETAILED DESCRIPTION
[0062] refer to Figure 1 , schematically showing a battery pack 10, which includes a housing 12 having a bottom shear plate 14, a top shear plate 16 and a side wall shell 18 (see Figure 2 A plurality of battery cells 20 are disposed within the housing 12. The battery cells 20 each include an electrical terminal 22 for connection to a bus bar or other system 23 for electrical connection. The battery cells 20 each include a vent 24 in communication with an array of vent channels 26.
[0063] like Figure 2 As shown in FIG. 1 , the channel array 26 connects the exhaust port 24 of each battery cell 20 to the battery pack exhaust port 28 provided in the housing 12 via the outlet hole 32 of the channel array 26 connected to the battery pack exhaust port 28. The channel array 26 includes a plurality of channels 34 separated by a series of ribs 36, and the ribs 36 include openings 38 to connect the exhaust port 24 of each battery cell 20 with the outlet hole 32 of the channel array 26.
[0064] For example, Figure 7 As shown in FIG. 1 , exhaust gas from battery cell 20x passes through channel 34x, through opening 38x in rib 36x, communicates to channel 34x+9, and along manifold path 39 to outlet port 32 as shown by the directional arrows. Figure 7 As shown in FIG. 1 , the ribs 36 include openings 38 to allow the exhaust ports 24 of the individual battery cells 20 to communicate through and across the channels 34 to the outlet holes 32. The channels 34 and openings 38 may have many alternative arrangements to communicate the gas from the battery cells 20 to the outlet holes 32. This system facilitates a longer gas travel path to allow the gas temperature to be reduced before the gas leaves the battery pack 10.
[0065] refer to Figure 2 , shows the channel array 26 which is comprised of interlocking channel plates 40 that interlock with adjacent channel plates 40 and connect individual battery cells to the outlet apertures 32 .
[0066] refer to Figure 3 and 4, the connection of the battery exhaust manifold 42 to the battery pack exhaust manifold 44 is achieved by a connector 46 inserted from the outside of the battery pack 10. The battery exhaust manifold 42 includes a cup-shaped body 48, which is sealingly connected to the channel plate 40 above the outlet hole 32. The battery exhaust manifold 42 includes a hole 50 in the side thereof. The battery pack exhaust manifold 44 supports the battery pack exhaust port 28 and includes an internal passage 52 extending from the battery pack exhaust port 28 to a pair of holes 54 receiving the connector 46. The connector 46 includes a slender rod 56, which has a passage 58 therein, which communicates with the end of the slender rod and the side hole 60, and the side hole 60 is aligned with the internal passage 52 of the battery pack exhaust manifold when the connector 46 is inserted into the hole 54. The connector 46 may include a head 62, which can be connected to the side wall 18 or the battery pack exhaust manifold 44 using fasteners 64 or other fastening techniques. Connector 46 utilizes a rubber foam gasket 65 around the hole 50 in the battery exhaust manifold 42, which seals over a large area to ensure that potting material cannot enter the exhaust system during the manufacturing process.
[0067] refer to Figure 5-6 , showing a channel array 26 including a battery cell joining plate 66 and a tray plate 68 that combine to define a channel 34 therebetween. The battery cell joining plate 66 and the tray plate 68 may be formed as injection molded parts. A breakable sheet 70 may be added below the battery cell joining plate 66 to thermally shield the remaining cells during a thermal runaway event of a single cell. A sealant may be added to help hold the breakable sheet 70 in place. The breakable sheet 70 may be made of mica, phenolic resin, or another thermoelastic but brittle material that may break in response to a thermal event of the battery cell 20. The battery cell joining plate 66 includes holes 72 that communicate with the exhaust ports of each battery cell 20. One of the battery cell joining plate 66 and the tray plate 68 includes ribs 36 to define the channels 34 of the channel array 26 that connect each hole 72 to the outlet hole 32. The ribs 36 may be sealed to the opposing battery cell joining plate 66 or tray plate 68 to provide a sealed channel 34. In addition, as Figure 6 As shown in FIG. 1 , scarf joints 74 are provided at the interface of adjacent battery cell joining plates 66. The gap between the scarf joints 74 is less than half the thickness of the battery cell joining plates 66 (typically less than 2-3 mm). Figure 1 As shown in , the battery pack 10 is at least partially filled with a potting material 76. The scarf joint 74 prevents the potting material 76 from entering the battery channel array 26. The joint 74 can be further sealed with a sealant or tape. The sealing can be achieved using at least one of mechanical connection, melt bonding, welding, solvent bonding and adhesive bonding. The entire exhaust system is sealed so that the potting material 76 cannot enter the system during the manufacturing process. The potting material 76 includes one of a blown foam, a syntactic foam and a non-foamed polymer resin.
[0068] With the passage 34 sealed, a foam or non-foam potting material 76 may be filled to the extent that it contacts the upper and lower shear plates 14, 16 so that the upper-lower shear plates can be connected by the potting material 76. Once the potting is in place, the exhaust system is fully sealed to trap the gas.
[0069] refer to Figure 8 , showing a thermal runaway sensor 80 mounted in the battery pack exhaust manifold 44 and communicating with the exhaust path 54 .
[0070] The battery pack 10 includes a closed ventilation system for conveying the gases exhausted from the battery experiencing thermal runaway and reducing its temperature. The purpose of creating such a closed system is to ensure that the potting material 66 used to encapsulate the battery cells 20 does not enter the exhaust system during the manufacturing process of the battery pack 10, and to contain and keep the hot exhaust away from the remaining battery cells 20.
[0071] The above description is only exemplary and is absolutely not intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be limited thereto, because after studying the drawings, the specification and the following claims, other modifications will become apparent. It should be understood that one or more steps in the method may be implemented in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described above as having certain features, any one or more features described in any embodiment of the present disclosure may be implemented in any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the embodiments are not mutually exclusive, and the mutual replacement of one or more embodiments is still within the scope of the present disclosure.
[0072] Various terms are used to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "on," "under," and "disposed." Unless explicitly described as "directly," when describing the relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship in which there are no other intervening elements between the first element and the second element, or an indirect relationship in which there are one or more intervening elements (spatially or functionally) between the first element and the second element. The phrase "at least one of A, B, and C" as used herein should be interpreted to mean a logical (A or B or C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."
Claims
1. A battery pack for a vehicle, comprising: a housing including at least one pack vent between an interior and an exterior of the housing; a plurality of battery cells disposed within the housing; and a vent system comprising a network of enclosed channels beneath the battery connected to the vents of the plurality of battery cells and the at least one battery pack vent; and A manifold is mounted on the closed channel network, and a portion of the manifold mounted on the housing includes a connector mounted externally into the housing that connects the manifold to the closed channel network. 2 . The battery pack for a vehicle according to claim 1 , wherein a pack mounted portion of the manifold includes a sealing material engaging the connector. 3 . 3 . The battery pack for a vehicle according to claim 2 , wherein the sealing material comprises rubber foam. 4 . The battery pack for a vehicle according to claim 1 , wherein the manifold connects passages from at least two modules to a single battery pack exhaust port. 5 . The battery pack for a vehicle according to claim 1 , further comprising a potting material filling all gaps outside the exhaust system. 6 . The battery pack for a vehicle according to claim 5 , wherein the potting material comprises one of blown foam, syntactic foam, and non-foamed polymer resin. 7 . The battery pack for a vehicle according to claim 1 , wherein the exhaust system is sufficiently sealed to prevent a potting material from entering the exhaust system during a battery pack manufacturing process. 8 . The battery pack for a vehicle according to claim 1 , wherein the closed channel network comprises a battery channel array.
9. The battery pack for a vehicle of claim 1, wherein the closed channel network comprises battery trays and vent tray stacks sealed together with other battery trays and vent tray stacks to create a sealed vent channel battery module. 10 . The battery pack for a vehicle according to claim 1 , further comprising a thermal runaway sensor in communication with the channel network.