Rechargeable energy storage system with unified battery cell holder vented tray and vented tray cover system

Abstract

A battery pack for a vehicle includes a housing including at least one battery pack vent between an interior and an exterior of the housing. A plurality of battery cells are contained within the housing. The channel tray includes an array of channels having a plurality of vent openings, each vent opening positioned to connect with a vent on each of the plurality of battery cells. The array of channels is connected to at least one vent of the housing, where the channel system is closed from the remaining volume of the battery pack, and the plurality of vent openings are each provided with a vent cover.

Description

Technical Field

[0001] The present disclosure relates to a battery cell array thermal runaway gas venting system using an intermediate battery channel system. Background Art

[0002] The information provided in this section is for the purpose of generally introducing the background of the present disclosure. To the extent described in this section, the work of the presently named inventors and aspects of the description that may not constitute prior art at the time of filing are neither explicitly nor implicitly admitted as prior art against the present disclosure.

[0003] Ventilating the battery cells of an electric vehicle's battery pack is known in the art. The vent system must remain open to allow gas to pass through during a thermal event so that the gas can reach the vents of the battery pack. The rest of the battery pack is typically filled with a potting resin (foam or non-foam) for electrical insulation, structural performance, and thermal insulation. Controlling the potting location is challenging. The variability of foam material expansion makes baseline systems 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 gas venting system. The closed volume will not be blocked by potting 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 battery pack vent located between an interior and an exterior of the housing. A plurality of battery cells are contained within the housing. A channel tray includes a channel array having a plurality of vent openings, each vent opening being positioned to connect with a vent on each of the plurality of battery cells. The channel array is connected to at least one vent of the housing, wherein the channel system is closed to the rest of the volume of the battery pack, and each of the plurality of vent openings is provided with a vent cover.

[0006] According to another aspect, the housing includes a potting material encapsulating the plurality of battery cells.

[0007] According to another aspect, the potting material is one of a foaming resin, a non-foaming resin, or a combination of a foaming resin and a non-foaming resin.

[0008] According to another aspect, the vent cover is configured to rupture in response to a thermal event of the battery cell.

[0009] According to another aspect, the vent cover is flame retardant.

[0010] According to another aspect, the vent cover is integrally formed with the battery cell engagement panel.

[0011] According to another aspect, the vent cover is connected to the battery cell engagement panel via a weakened material area.

[0012] According to another aspect, the vent cover is electrically insulating.

[0013] According to another aspect, the vent cover is made of a material including one of PA 66, PA6, PP, PU, ​​epoxy resin, silicone, PE, mica, PS, PVC, ABS, PET, POM, PTFE, PMMA, PC, plastic containing glass fiber and plastic containing flame retardant.

[0014] According to another aspect, the vent cover is made of PA 66 containing up to 50% glass fibers.

[0015] According to another aspect, the vent cover is made of a foam material.

[0016] According to another aspect, the vent cover comprises a separate battery cell cover.

[0017] According to another aspect, the vent cover is formed as a vent cover strip.

[0018] According to another aspect, an aisle tray includes a battery cell engagement panel and a tray panel, the battery cell engagement panel including a plurality of vent openings therein.

[0019] According to another aspect, the housing includes a bottom shear panel and an upper shear panel, the cell engagement panel and the tray panel include an injection channel extending therethrough, wherein the injection channel is configured to allow injection of potting material through the injection channel and between the bottom shear panel and the tray panel.

[0020] According to another aspect, a housing includes a potting material encapsulating a plurality of battery cells and a channel tray, and is bonded to the bottom shear panel and the upper shear panel.

[0021] According to another aspect, a battery pack for a vehicle includes a housing including at least one battery pack vent located between an interior and an exterior of the housing. A plurality of battery cells are contained within the housing. A channel tray includes a channel array having a plurality of vent openings, each vent opening being positioned to connect with a vent on each of the plurality of battery cells, and the channel array is connected to at least one vent of the housing. The channel system is closed to the rest of the volume of the battery pack, and the plurality of vent openings are each provided with a vent cover, wherein the channel tray includes a plurality of panel assemblies, each panel assembly including a battery cell engagement panel and a tray panel, the battery cell engagement panel including a plurality of battery cell vent openings, and the plurality of panel assemblies including a convex engagement portion that engages with a concave engagement portion of an adjacent panel assembly.

[0022] According to another aspect, the housing includes bottom and upper shear panels, the cell engagement panels and the tray panels include injection channels extending therethrough, wherein the housing contains a potting material encapsulating a plurality of cells and the channel tray and is bonded to the bottom and upper shear panels.

[0023] According to another aspect, a battery pack for a vehicle includes a housing including at least one battery pack vent located between an interior and an exterior of the housing. A plurality of battery cells are disposed within the housing. A channel tray includes a channel array having a plurality of vent openings, each vent opening being positioned to connect with a vent on each of the plurality of battery cells, and the channel array is connected to at least one vent of the housing, wherein the channel system is closed from the remainder of the volume of the battery pack, and the plurality of vent openings are each provided with a vent cover, wherein the housing includes a bottom shear plate and an upper shear plate, wherein the housing contains a potting material that encapsulates the plurality of battery cells and the channel tray, and is bonded to the bottom shear plate and the upper shear plate.

[0024] According to another aspect, the housing includes a bottom shear panel and an upper shear panel, the cell engagement panel and the tray panel include an injection channel extending therethrough, wherein the injection channel is configured to allow injection of potting material through the injection channel and between the bottom shear panel and the tray panel.

[0025] The present invention provides the following technical solutions:

[0026] 1. A battery pack for a vehicle, comprising:

[0027] a housing including at least one battery pack vent between an interior and an exterior of the housing;

[0028] a plurality of battery cells disposed within the housing; and

[0029] A channel tray comprising a channel array having a plurality of vent openings, each vent opening being positioned to connect with a vent on each of a plurality of battery cells, and the channel array being connected with at least one vent of a housing, wherein the channel system is closed to the rest of the volume of the battery pack and each of the plurality of vent openings is provided with a vent cover.

[0030] 2 . The battery pack for a vehicle according to claim 1 , wherein the case includes a potting material encapsulating the plurality of battery cells.

[0031] 3 . The battery pack for a vehicle according to claim 2 , wherein the potting material is one of a foamed resin, a non-foamed resin, or a combination of a foamed resin and a non-foamed resin.

[0032] 4 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is configured to rupture in response to a thermal event of the battery cell.

[0033] 5 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is flame retardant.

[0034] 6 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is formed integrally with the battery cell joint panel.

[0035] 7 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is connected to the battery cell joining panel through a weakened material area.

[0036] 8 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is electrically insulating.

[0037] 9. The battery pack for a vehicle according to claim 1, wherein the vent cover is made of a material including one of PA 66, PA6, PP, PU, ​​epoxy resin, silicone resin, PE, mica, PS, PVC, ABS, PET, POM, PTFE, PMMA, PC, plastic containing glass fiber, and plastic containing flame retardant.

[0038] 10 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is made of PA 66 containing up to 50% of glass fiber.

[0039] 11 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is made of a foam material.

[0040] 12 . The battery pack for a vehicle according to claim 1 , wherein the vent cover comprises an independent battery cell cover.

[0041] 13 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is formed as a strip of a vent cover.

[0042] 14 . The battery pack for a vehicle according to claim 1 , wherein the channel tray comprises a battery cell engaging panel and a tray panel, the battery cell engaging panel including the plurality of vent openings therein.

[0043] 15. The battery pack for a vehicle according to claim 14, wherein the housing includes a bottom shear plate and an upper shear plate, the battery cell engaging panel and the tray panel include an injection channel extending therethrough, wherein the injection channel is configured to allow potting material to be injected through the injection channel and between the bottom shear plate and the tray panel.

[0044] 16 . The battery pack for a vehicle according to claim 15 , wherein the case includes a potting material encapsulating the plurality of battery cells and the channel tray, and is bonded to the bottom shear panel and the upper shear panel.

[0045] 17. A battery pack for a vehicle, comprising:

[0046] a housing including at least one battery pack vent between an interior and an exterior of the housing;

[0047] a plurality of battery cells disposed within the housing; and

[0048] A channel tray, the channel tray comprising a channel array having a plurality of battery cell vent openings, each battery cell vent opening being positioned to connect with a vent on each of a plurality of battery cells, and the channel array being connected with at least one vent of a housing, wherein the channel tray comprises a plurality of panel assemblies, each panel assembly comprising a battery cell engaging panel and a tray panel, the battery cell engaging panel including a plurality of battery cell vent openings therein, the plurality of panel assemblies comprising a convex engaging portion that engages with a concave engaging portion of an adjacent panel assembly.

[0049] 18. A battery pack for a vehicle according to claim 17, wherein the housing includes a bottom shear panel and an upper shear panel, the battery cell engagement panel and the tray panel include channels extending therethrough, wherein the housing contains a potting material encapsulating the plurality of battery cells and the channel tray and is bonded to the bottom shear panel and the upper shear panel.

[0050] 19. A battery pack for a vehicle, comprising:

[0051] a housing including at least one battery pack vent between an interior and an exterior of the housing;

[0052] a plurality of battery cells disposed within the housing; and

[0053] A channel tray, the channel tray comprising a channel array having a plurality of vent openings, each vent opening being positioned to connect with a vent on each of a plurality of battery cells, and the channel array being connected to at least one vent of a shell, wherein the channel system is closed from the remaining volume of the battery pack, the plurality of vent openings are each provided with a vent cover, wherein the shell comprises a bottom shear plate and an upper shear plate, wherein the shell contains a potting material encapsulating the plurality of battery cells and the channel tray, and is bonded to the bottom shear plate and the upper shear plate.

[0054] 20. The battery pack for a vehicle according to claim 19, wherein the housing includes a bottom shear plate and an upper shear plate, the battery cell engaging panel and the tray panel include a channel extending therethrough, wherein the channel is configured to allow potting material to pass through the channel and be injected between the bottom shear plate and the tray panel.

[0055] 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

[0056] The present disclosure will be more fully understood from the detailed description and accompanying drawings, in which:

[0057] Figure 1 is a partial cross-sectional view of a battery pack having a venting system according to the principles of the present disclosure;

[0058] Figure 2 is a schematic diagram of a battery pack having a vent system having an array of channels connecting each battery cell to a main channel;

[0059] Figure 3 is a detailed view of an alternative connection between the channel array and the battery pack ventilation manifold;

[0060] Figure 4 is a schematic diagram of an integrally formed vent cover of a battery cell joint panel;

[0061] Figure 5 is a schematic diagram of a separately formed vent cover;

[0062] Figure 6 is a schematic diagram of a vent cover formed separately in a strip shape;

[0063] Figure 7 is a bottom view of a battery cell junction panel having injection channels;

[0064] Figure 8 is a schematic diagram of an injection channel in a channel array;

[0065] Fig. 9 is a schematic diagram of a potting process for encapsulating a battery cell and a channel array and bonding to an upper shear plate and a bottom shear plate;

[0066] Fig.10a and Fig.10b A process for forming a channel array according to the principles of the present disclosure is shown;

[0067] Fig.11 is a schematic diagram of the interconnections between the panel components; and

[0068] Fig.12 is a schematic diagram of alternative interconnections between panel components.

[0069] Among the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0070] refer to Figure 1 , schematically shows a battery pack 10, which includes a bottom shear plate 14, a top shear plate 16 and a side wall shell 18 (see Figure 2 ) of a housing 12. A plurality of battery cells 20 are disposed within the housing 12. The battery cells 20 each include an electrical terminal 22 for connecting to a bus bar or other system 23 for electrical connection. The battery cells 20 are supported by a channel array 26. The channel array 26 includes a plurality of battery cell engagement panels 50 supported above a plurality of tray panels 52. The battery cell engagement panel 50 includes a vent opening 38 associated with each of the plurality of battery cells 20. A series of ribs 36 may be formed on either or both of the battery cell engagement panel 50 and the tray panel 52 to define a channel 34 between the battery cell engagement panel 50 and the tray panel 52. Each of the battery cells 20 includes a vent 24 that is in communication with a corresponding one of the openings 38 through a battery cell vent cover 27 that is one of rupturable, breakable, tearable, meltable, or otherwise openable in response to a battery cell thermal event. The battery cell vent cover 27 is configured or made of such a material that the battery cell vent cover 27 should rupture in response to a thermal event of the battery cell 20 placed against the vent cover, and should absorb or dissipate sufficient energy in the process so that the adjacent battery cell or any other vent cover is not ruptured. The battery cell vent cover 27 can be made of a material including one of PA 66, PA6, PP, PU, ​​epoxy resin, silicone resin, PE, mica, PS, PVC, ABS, PET, POM, PTFE, PMMA, PC, a plastic containing glass fiber, and a plastic containing a flame retardant, but other materials can also be used. As a non-limiting example, the battery cell vent cover 27 can be made of PA 66 containing up to 50% glass fiber. The potting material 70 can encapsulate the battery cell 20.

[0071] like Figure 2 As shown, the channel array 26 can connect the vent 24 of each battery cell 20 to the battery pack vent 28 disposed in the housing 12 via a main channel 30, and the main channel 30 connects the outlet port 32 of the channel array 26 to the battery pack vent 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 for connecting the vent 24 of each battery cell 20 to the outlet port 32 of the channel array 26.

[0072] For example, if Figure 2 As shown, the vent from the battery cell 20x communicates through the channel 34x, through the opening 38x in the rib 36x, to the channel 34x-1 to the outlet port 32, as shown by the directional arrows. Figure 2 As shown, the ribs 36 include openings 38 to allow the vents 24 of each battery cell 20 to pass through and across the channels 34 to communicate to the outlet ports 32. The channels 34 and openings 38 may be provided with a variety of alternative arrangements for communicating the gases from the battery cells 20 to the outlet ports 32. The system readily implements a longer gas travel path to allow the gas temperature to be reduced before the gas leaves the battery pack.

[0073] Alternatively, refer to Figure 3 The channel array manifold 42 may connect the channels 34 to a battery pack vent manifold 44 that includes connecting channels 46 , 48 that communicate with the battery pack vents 28 .

[0074] refer to Figure 4 , the cell vent cover 27 may be integrally formed with the cell engagement panel 50, wherein an area of ​​thin or weakened material 54 may support the cell vent cover 27 within the opening 38 of the cell engagement panel 50. The thin or weakened material 54 may be configured to rupture or break in response to a cell thermal event.

[0075] refer to Figure 5 , the battery cell vent cover 127 is shown as being formed separately from the battery cell engagement panel 50 and placed in the opening 38. The battery cell vent cover 127 includes a tapered outer side wall 128 that engages the tapered inner side wall 130 of the opening 38 in the battery cell engagement panel 50. The battery cell vent cover 127 can be made of a material including one of PA 66, PA6, PP, PU, ​​epoxy resin, silicone resin, PE, mica, PS, PVC, ABS, PET, POM, PTFE, PMMA, PC, plastic containing glass fiber, and plastic containing flame retardant. As a non-limiting example, the battery cell vent cover 127 can be made of PA 66 containing up to 50% glass fiber. The battery cell vent cover 127 is configured to be bent, broken, or otherwise squeezed through the opening in response to a thermal event of the battery cell 20.

[0076] refer to Figure 6, a strip 228 of a cell vent cover 227 is shown, wherein the cell vent covers 227 are connected to each other. The strip 228 is formed separately from the cell engagement panel 50 and is positioned so that the cell vent cover 227 is disposed in the opening 38. The cell vent cover 227 may include a tapered outer sidewall 230 that engages a tapered inner sidewall 232 of the opening 38 in the cell engagement panel 50. The cell vent cover 227 may be made of a material including one of PA66, PA6, PP, PU, ​​epoxy resin, silicone resin, PE, mica, PS, PVC, ABS, PET, POM, PTFE, PMMA, PC, a plastic containing glass fiber, and a plastic containing a flame retardant. As a non-limiting example, the cell vent cover 227 may be made using PA 66 containing up to 50% glass fiber. The battery cell vent cover 227 is configured to break from the strap 228 and may break, bend, or otherwise squeeze through the opening 38 in response to a thermal event of the battery cell 20 .

[0077] refer to Figure 7-9 , the channel array 326 may include channels 328 passing through the battery cell interface panel 50 and the tray panel 52. The channels 328 may be circular, such as Figure 7 and Figure 8 328 and is configured to allow potting material to be injected between the bottom shear plate and the tray panel through the channel 328. The channel 328 can be formed separately from the rib 36 or integrally formed in the rib 36. Figure 7 As shown, the battery cell engagement panel 50 includes an aperture 330 that can accommodate an accessory 332 ( Figure 8 ), for isolating channel 328 from channel 34. Fig. 9 , shows a schematic cross-sectional view of a battery case including a channel array 326 having elongated channels 328' therethrough that allow potting material 334 to pass through the channel array and fill the area below the channel array 326. The elongated channels 328' may be formed between a pair of ribs 36 extending from either the battery cell engagement panel 50 or the tray panel 52 and communicate with an elongated opening 340 on the other of the battery cell engagement panel 50 and the tray panel 52. The potting material 334 may be bonded to the bottom shear panel 14 and the top shear panel 16 while encapsulating the channel array and the battery cells 20. Thus, the potting material 334 may interconnect the bottom shear panel 14 to the top shear panel 16.

[0078] refer to Fig.10a and 10b, the cell engagement panel 50 may be formed with raised ribs 36, and the tray panel 52 may be molded to the cell engagement panel 50 so as to provide a sealing engagement with the raised ribs 36. The channel 34 may be formed by a core element that may be dissolved or otherwise removed to define the channel 34.

[0079] refer to Fig.11 , the channel array 26 can be formed by a plurality of panel assemblies 100, each panel assembly 100 including a battery cell engaging panel 50 and a tray panel 52 that can be interconnected. The panel assemblies 100 are placed side by side. The panel assemblies 100 include a male engaging portion 102 on one edge and a female engaging portion 104 on a second edge, wherein the male engaging portion 102 of the panel assembly 100 engages with the female engaging portion 104 of the adjacent panel assembly 100 to connect the channels 34. The channels 34 can be formed with a single male engaging portion 102 and a female engaging portion 104, or alternatively formed with their own male engaging portion 102' and a single female engaging portion 104', such as Fig.12 The sealing engagement between the panel assemblies 100 may be enhanced using a seal around the male engagement portion and an interlock between adjacent panel assemblies 100 .

[0080] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because after studying the drawings, the specification and the appended claims, other modifications will become apparent. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described as having certain features above, any one or more of those features described with respect to any embodiment of the present disclosure can 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 described embodiments are not mutually exclusive, and the replacement of one or more embodiments with each other is still within the scope of the present disclosure.

[0081] Various terms are used, including "connected," "engaged," "coupled," "adjacent," "next to," "on," "above," "below," and "disposed," to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.). Unless explicitly described as "direct," when a relationship between a first element and a second element is described in the above disclosure, the relationship can be a direct relationship in which there are no other intermediate elements between the first element and the second element, but can also be an indirect relationship in which there are one or more intermediate elements (spatially or functionally) between the first element and the second element. As used herein, the phrase at least one of A, B, and C 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 battery pack vent between an interior and an exterior of the housing; a plurality of battery cells disposed within the housing; and A channel tray comprising a channel array having a plurality of vent openings, each vent opening being positioned to connect with a vent on each of a plurality of battery cells, and the channel array being connected with at least one vent of a housing, wherein the channel system is closed to the rest of the volume of the battery pack and each of the plurality of vent openings is provided with a vent cover.

2. The battery pack for a vehicle according to claim 1, wherein: The housing includes a potting material encapsulating the plurality of battery cells.

3. The battery pack for a vehicle according to claim 2, wherein: The potting material is one of a foaming resin, a non-foaming resin, or a combination of a foaming resin and a non-foaming resin.

4. The battery pack for a vehicle according to claim 1, wherein: The vent cover is configured to rupture in response to a thermal event of the battery cell.

5. The battery pack for a vehicle according to claim 1, wherein: The vent cover is flame retardant.

6. The battery pack for a vehicle according to claim 1, wherein: The vent cover is integrally formed with the battery cell engagement panel. 7 . The battery pack for a vehicle according to claim 1 , wherein the vent cover is connected to the battery cell joining panel through a weakened material area.

8. The battery pack for a vehicle according to claim 1, wherein: The vent cover is electrically insulating.

9. The battery pack for a vehicle according to claim 1, wherein: The vent cover is made of a material including one of PA 66, PA6, PP, PU, ​​epoxy resin, silicone resin, PE, mica, PS, PVC, ABS, PET, POM, PTFE, PMMA, PC, plastic containing glass fiber, and plastic containing flame retardant.

10. The battery pack for a vehicle according to claim 1, wherein: The vent cover is made of PA 66 containing up to 50% glass fiber.

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