Thermal blanket system for use within traction battery pack

Abstract

A thermal blanket system for use within a traction battery pack is provided. An example thermal barrier blanket system may include a plurality of thermal barrier panels arranged in an overlapping configuration. The thermal barrier panels may be arranged such that during a battery thermal event, battery exhaust gases and / or other effluents are forced across the top of the downstream thermal barrier panel, thereby slowing the inter-array propagation time and maintaining the structural integrity of the surrounding enclosure structure.

Description

Technical Field

[0001] The present disclosure relates generally to electrified vehicle traction battery packs, and more particularly to a thermal barrier blanket system for use within a battery array of a traction battery pack. Background Art

[0002] A high voltage traction battery pack typically supplies power to the electric motor and other electrical loads of an electrified vehicle. The traction battery pack includes a plurality of battery cells and various other battery internal components that support the electric propulsion of the vehicle. Summary of the invention

[0003] A traction battery pack according to an exemplary aspect of the present disclosure includes, among other things, a thermal barrier blanket system including a first thermal barrier panel at least partially overlapping a second thermal barrier panel.

[0004] In another non-limiting embodiment of the foregoing traction battery pack, a first thermal barrier panel covers a first battery array, and a second thermal barrier panel covers a second battery array adjacent to the first battery array.

[0005] In another non-limiting embodiment of any of the foregoing traction battery packages, the first thermal barrier panel includes a second lateral edge flange that overlaps the first lateral edge flange of the second thermal barrier panel.

[0006] In another non-limiting embodiment of any of the foregoing traction battery packs, the first lateral edge flange includes a cup-shaped portion configured to engage the post.

[0007] In another non-limiting embodiment of any of the foregoing traction battery packs, the brace is attached to a cross-member beam located between a first battery array below the first thermal barrier panel and a second battery array below the second thermal barrier panel.

[0008] In another non-limiting embodiment of any of the foregoing traction battery packs, the first thermal barrier panel is secured to the strut by fasteners.

[0009] In another non-limiting embodiment of any of the foregoing traction battery packages, the first lateral edge flange includes an inclined surface that establishes a portion of the gas path that extends over a top of the second thermal barrier panel.

[0010] In another non-limiting embodiment of any of the foregoing traction battery packs, the gas path additionally extends between a top cover of the first battery array and the first thermal barrier panel.

[0011] In another non-limiting embodiment of any of the foregoing traction battery packs, the first thermal barrier panel and the second thermal barrier panel each include a flame resistant and heat insulation material.

[0012] In another non-limiting embodiment of any of the foregoing traction battery packs, the flame retardant insulation material includes mica, aerogel material, and / or refractory ceramic fibers.

[0013] A traction battery pack according to another exemplary aspect of the present disclosure includes, inter alia: a first battery array, the first battery array being covered by a first thermal barrier panel of a thermal barrier blanket system; and a second battery array, the second battery array being covered by a second thermal barrier panel of the thermal barrier blanket system. Each of the first thermal barrier panel and the second thermal barrier panel includes a first lateral edge flange and a second lateral edge flange. The second lateral edge flange of the first thermal barrier panel at least partially overlaps the first lateral edge flange of the second thermal barrier panel.

[0014] In another non-limiting embodiment of the foregoing traction battery pack, a cross member beam is located between the first battery array and the second battery array.

[0015] In another non-limiting embodiment of any of the foregoing traction battery packages, a brace is attached to the cross-member beam.

[0016] In another non-limiting embodiment of any of the foregoing traction battery packages, the first lateral edge flange of the second thermal barrier panel includes a cup-shaped portion configured to engage the post.

[0017] In another non-limiting embodiment of any of the foregoing traction battery packs, the first thermal barrier panel is secured to the strut by fasteners.

[0018] In another non-limiting embodiment of any of the foregoing traction battery packages, the first lateral edge flange of the second thermal barrier panel includes an inclined surface that establishes a portion of the gas path extending over a top of the second thermal barrier panel.

[0019] In another non-limiting embodiment of any of the foregoing traction battery packs, the gas path additionally extends between a top cover of the first battery array and the first thermal barrier panel.

[0020] In another non-limiting embodiment of any of the foregoing traction battery packs, the gas path additionally extends between a second lateral edge flange of the first thermal barrier panel and a first lateral edge flange of the second thermal barrier panel.

[0021] In another non-limiting embodiment of any of the foregoing traction battery packs, the first thermal barrier panel and the second thermal barrier panel each include a flame retardant insulating material.

[0022] In another non-limiting embodiment of any of the foregoing traction battery packs, the flame retardant insulation material includes mica, aerogel material, and / or refractory ceramic fibers.

[0023] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings (including any of their various aspects or corresponding individual features) may be adopted independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible.

[0024] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 An electrified vehicle is schematically shown.

[0026] Figure 2 is a perspective view of a traction battery pack for an electrified vehicle.

[0027] Figure 3 yes Figure 2 Cross-sectional view of a traction battery pack.

[0028] Figure 4 is a top view of a thermal barrier blanket system for use within a traction battery pack.

[0029] Figure 5 yes Figure 4 Side view of a thermal barrier blanket system.

[0030] Figure 6 yes Figure 5 An angled magnified view of a portion of a thermal barrier blanket system.

[0031] Figure 7 The gas paths established between adjacent cell arrays by the thermal barrier blanket system are schematically shown. DETAILED DESCRIPTION

[0032] The present disclosure details an exemplary thermal barrier blanket system for use within a traction battery pack. An exemplary thermal barrier blanket system may include a plurality of thermal barrier panels arranged in an overlapping configuration. The thermal barrier panels may be arranged such that during a battery thermal event, battery exhaust gases and / or other effluents are forced over the top of the downstream thermal barrier panels, thereby slowing inter-array propagation times and maintaining the structural integrity of the surrounding enclosure structure. These and other features are discussed in more detail in the following paragraphs of this detailed description.

[0033] Figure 1An electrified vehicle 10 is schematically shown. The electrified vehicle 10 may include any type of electrified powertrain. In an embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and may be extended to other electrified vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, and the like. Therefore, although not specifically shown in the exemplary embodiment, the powertrain of the electrified vehicle 10 may be equipped with an internal combustion engine, which may be employed alone or in combination with other power sources to propel the electrified vehicle 10.

[0034] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 may alternatively be a sport utility vehicle (SUV), a van, a pickup truck, or any other vehicle configuration. Although specific component relationships are shown in the drawings of the present disclosure, the drawings are not intended to limit the present disclosure. The placement and orientation of the various components of the electrified vehicle 10 are schematically shown and may vary within the scope of the present disclosure. In addition, the various drawings attached to the present disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to emphasize certain details of a particular component or system.

[0035] In the illustrated embodiment, the electrified vehicle 10 is a pure electric vehicle that is propelled solely by electricity, such as by one or more electric machines 12, without assistance from an internal combustion engine. The electric machines 12 may operate as electric motors, generators, or both. The electric machines 12 receive electricity and may convert the electricity into torque for driving one or more wheels 14 of the electrified vehicle 10.

[0036] Voltage bus 16 may electrically couple electric machine 12 to traction battery pack 18. Traction battery pack 18 is an exemplary electrified vehicle battery. Traction battery pack 18 may be a high voltage traction battery pack assembly that includes a plurality of battery cells capable of outputting electrical power to power electric machine 12 and / or other electrical loads of electrified vehicle 10. Other types of energy storage devices and / or output devices may alternatively or additionally be used to power electrified vehicle 10.

[0037] The traction battery pack 18 may be secured to an underbody 20 of the electrified vehicle 10 . However, the traction battery pack 18 may be located elsewhere on the electrified vehicle 10 within the scope of the present disclosure.

[0038] Figure 2 and Figure 3Additional details are shown associated with the traction battery pack 18 of the electrified vehicle 10. The traction battery pack 18 may include one or more battery arrays 22 (e.g., battery assemblies or groups of rechargeable battery cells 24) capable of outputting electrical power to power the electric machine 12 and / or other electrical loads of the electrified vehicle 10. Other types of energy storage devices and / or output devices may alternatively or additionally be used to power the electrified vehicle 10.

[0039] The battery cells 24 may be stacked side by side along a stacking axis to form a group of battery cells 24, sometimes referred to as a "cell stack." Figure 3 In the highly schematic depiction of FIG. 1 , the battery cells 24 are stacked into the page in one direction to construct each battery array 22, and thus the battery array 22 may extend in the vehicle transverse direction. However, other configurations are possible. The total number of battery arrays 22 and battery cells 24 provided within the traction battery pack 18 is not intended to limit the present disclosure.

[0040] In one embodiment, the battery cells 24 of each battery array 22 are prismatic lithium-ion cells. However, within the scope of the present disclosure, battery cells having other geometries (cylindrical, pouch, etc.), other chemistries (nickel metal hydride, lead acid, etc.), or both may alternatively be utilized.

[0041] The battery array 22 and various other battery internal components (e.g., bus electrical center, battery electrical control module, wiring, connectors, etc.) can be housed within the interior area 26 of the housing assembly 28. The housing assembly 28 can include a housing cover 30 and a housing tray 32. The housing cover 30 can be fastened (e.g., bolted, welded, adhered, etc.) to the housing tray 32 to provide the interior area 26. The size, shape, and overall configuration of the housing assembly 28 are not intended to limit the present disclosure.

[0042] Sometimes, pressure and heat energy inside one or more of the battery cells 24 may increase during a battery thermal event, such as, for example, a battery thermal event caused by an overcharge condition, an over-discharge condition, or a short circuit event. The pressure and heat energy increase may cause the associated battery cell 24 to generate relatively large amounts of heat, and in some rare cases, may cause battery exhaust gases and / or other effluents to be released from the interior of the associated battery cell 24.

[0043] The traction battery pack 18 may include a thermal barrier blanket system 34 configured to manage / mitigate the effects of battery thermal events. Among other benefits, the thermal barrier blanket system 34 may be configured to manage inter-array propagation of battery cell exhaust gases and / or effluents, and may further confine the exhaust gases and / or effluents and associated heat from impacting the structural integrity of the housing cover 30 and / or housing tray 32.

[0044] The thermal barrier blanket system 34 may be positioned within the interior region 26 of the enclosure assembly 28. In one embodiment, the thermal barrier blanket system 34 is disposed in the space between the battery array 22 and the enclosure cover 30. However, other configurations are contemplated within the scope of the present disclosure.

[0045] Figure 4 , Figure 5 and Figure 6 Additional details associated with the thermal barrier blanket system 34 of the traction battery pack 18 are shown. The thermal barrier blanket system 34 may include a plurality of thermal barrier panels 36. In the illustrated embodiment, the thermal barrier blanket system 34 includes a total of ten thermal barrier panels 36. However, a greater or lesser number of thermal barrier panels 36 may be provided within the scope of the present disclosure. Typically, the number of thermal barrier panels 36 provided as part of the thermal barrier blanket system 34 will match the number of battery arrays 22 provided within the traction battery pack 18.

[0046] Each thermal barrier panel 36 may provide a blanket design arranged to cover one of the battery arrays 22 of the traction battery pack 18. The battery array 22 is Figure 4 Schematically shown in FIG, but for simplicity Figure 5 and Figure 6 is omitted.

[0047] One or more of the thermal barrier panels 36 may be configured differently than the other thermal barrier panels 36 of the thermal barrier blanket system 34. The thermal barrier panels 36 may be configured differently in size, shape, features, etc.

[0048] Each thermal barrier panel 36 may be arranged to overlap at least one adjacent thermal barrier panel 36 to establish a "shingled" or "shipping" configuration of the thermal barrier blanket system 34. For example, each thermal barrier panel 36 may include a first lateral edge flange 38 and a second lateral edge flange 40. For example, the first lateral edge flange 38 and the second lateral edge flange 40 may extend parallel to the longitudinal axis of each battery array 22. Figure 6 As best shown in FIG. 1 , the second lateral edge flange 40 of at least some of the thermal barrier panels 36 may be arranged to overlap portions of the first lateral edge flange 38 of an adjacent thermal barrier panel 36 .

[0049] Each thermal barrier panel 36 may include a flame retardant insulating material 42 (at Figure 6 ). The flame retardant insulation material 42 may include mica, aerogel material, refractory ceramic fiber, etc., however, other materials or combinations of materials may be utilized within the scope of the present disclosure to provide flame retardant insulation properties within each thermal barrier panel 36.

[0050] Reference now Figure 7The cross member beam 44 may be disposed between a group of adjacent battery arrays 22A, 22B of the traction battery pack 18. The battery arrays 22A, 22B may be fixed relative to the housing tray 32 via the cross member beam 44.

[0051] The struts 46 may be mounted to the cross member beams 44. Fasteners 48 may be inserted through the thermal barrier panels 36A of the thermal barrier blanket system 34 and into the struts 46 to mount the thermal barrier panels 36A to the struts 46.

[0052] The thermal barrier panel 36A may be installed such that the second lateral edge flange 40 of the thermal barrier panel 36A overlaps the first lateral edge flange 38 of another thermal barrier panel 36B of the thermal barrier blanket system 34. The first lateral edge flange 38 of the thermal barrier panel 36B may include a cup surface 50 that interfaces with the post 46. For example, the cup surface 50 may be received around a portion of the post 46 to secure the thermal barrier panel 36B in place.

[0053] The first lateral edge flange 38 of the thermal barrier panel 36B may also include an inclined surface 52. The inclined surface 52 may function as a blocking structure, as discussed further below.

[0054] For example, when a battery thermal event occurs in the battery array 22A, the thermal barrier panel 36A can diffuse the speed of the exhaust gas and / or other effluents released from the source battery cell 24, thereby protecting the housing cover 30. Then, the diffused battery exhaust gas and / or other effluents can travel downstream from the battery array 22A along the gas path P. The gas path P can extend in the channel 54 between the thermal barrier panel 36A and the top cover 56 of the battery array 22A, and then pass over the top of the thermal barrier panel 36B via the inclined surface 52, which serves as a blocking structure for preventing gas and / or effluents from traveling between the thermal barrier panel 36B and the battery array 22B. Alternatively, the gas and / or other effluents are forced to flow over the thermal barrier panel 36B, thereby slowing down the inter-array propagation time and protecting the battery array 22B from the high temperature associated with the exhaust gas and / or effluents.

[0055] The exemplary thermal barrier blanket system of the present disclosure is designed to manage the effects of battery thermal events within a traction battery pack. The system may provide numerous advantages over known solutions, including but not limited to presenting a novel configuration that significantly slows inter-array propagation time while also maintaining the structural integrity of the battery outer housing structure.

[0056] Although different non-limiting embodiments are shown as having specific components or steps, the embodiments of the present disclosure are not limited to these specific combinations. Some components or features from any one of the non-limiting embodiments may be used in combination with features or components from any one of the other non-limiting embodiments.

[0057] It should be understood that like reference numerals indicate corresponding or similar elements throughout the several drawings.It should be understood that although particular component arrangements are disclosed and shown in these exemplary embodiments, other arrangements may benefit from the teachings of the present disclosure.

[0058] The above description should be interpreted as illustrative and not in any limiting sense. It will be appreciated by those skilled in the art that certain modifications may occur within the scope of the present disclosure. For these reasons, the attached claims should be studied to determine the true scope and content of the present disclosure.

Claims

1. A traction battery pack, comprising: A thermal barrier blanket system includes a first thermal barrier panel at least partially overlapping a second thermal barrier panel.

2. The traction battery pack of claim 1, wherein the first thermal barrier panel covers a first battery array, and the second thermal barrier panel covers a second battery array adjacent to the first battery array.

3. The traction battery pack of claim 1 or 2, wherein the first thermal barrier panel comprises a second lateral edge flange, the second lateral edge flange overlapping the first lateral edge flange of the second thermal barrier panel. 4 . The traction battery pack of claim 3 , wherein the first lateral edge flange includes a cup-shaped portion configured to engage a post.

5. The traction battery pack of claim 4, wherein the brace is attached to a cross member beam located between a first battery array below the first thermal barrier panel and a second battery array below the second thermal barrier panel, and optionally wherein the first thermal barrier panel is secured to the brace by fasteners.

6. The traction battery package of claim 3, wherein the first lateral edge flange includes an inclined surface that establishes a portion of the gas path that extends over a top of the second thermal barrier panel.

7. The traction battery pack of claim 6, wherein the gas path further extends between a top cover of the first battery array and the first thermal barrier panel.

8. A traction battery pack according to any preceding claim, wherein the first thermal barrier panel and the second thermal barrier panel each comprise a flame retardant insulating material, and optionally wherein the flame retardant insulating material comprises mica, an aerogel material and / or a refractory ceramic fiber.

9. A traction battery pack, comprising: a first battery array, the first battery array being covered by a first thermal barrier panel of a thermal barrier blanket system; and a second battery array, the second battery array being covered by a second thermal barrier panel of the thermal barrier blanket system, wherein each of the first thermal barrier panel and the second thermal barrier panel comprises a first lateral edge flange and a second lateral edge flange, and Wherein the second lateral edge flange of the first thermal barrier panel at least partially overlaps the first lateral edge flange of the second thermal barrier panel.

10. The traction battery pack of claim 9 including a cross member beam located between the first battery array and the second battery array.

11. The traction battery package of claim 10, comprising a brace attached to the cross member beam, and optionally wherein the first thermal barrier panel is secured to the brace by fasteners.

12. The traction battery package of claim 11, wherein the first lateral edge flange of the second thermal barrier panel includes a cup-shaped portion configured to engage the support post.

13. The traction battery pack of any one of claims 9 to 12, wherein the first lateral edge flange of the second thermal barrier panel includes an inclined surface that establishes a portion of a gas path that extends over a top of the second thermal barrier panel.

14. The traction battery pack of claim 13, wherein the gas path additionally extends between a top cover of the first battery array and the first thermal barrier panel, and optionally, wherein the gas path additionally extends between the second lateral edge flange of the first thermal barrier panel and the first lateral edge flange of the second thermal barrier panel.

15. The traction battery pack of any one of claims 9 to 14, wherein the first thermal barrier panel and the second thermal barrier panel each comprise a flame retardant thermal insulation material, and optionally wherein the flame retardant thermal insulation material comprises mica, aerogel material and / or refractory ceramic fibers.

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