Battery module including exhaust manifold having selectively activated fluid inlet

Abstract

According to a non-limiting example, a battery module includes a module housing including a plurality of walls defining an interior and a plurality of battery cells disposed in the interior. Each of the plurality of battery cells includes an exhaust port. An exhaust manifold is connected to each of the plurality of battery cells. The exhaust manifold includes a central passage fluidly connected with an exhaust port in each of the plurality of battery cells and a fluid inlet selectively allowing an amount of fluid to pass into a selected one of the plurality of battery cells.

Description

Technical Field

[0001] The present invention relates to the field of battery assemblies, and more particularly, to a battery module including an exhaust manifold having a selectively activated fluid inlet. Background Art

[0002] Rechargeable battery systems typically include a plurality of connected battery cells arranged in a housing to form a battery module. A plurality of battery modules are connected and arranged in a housing to form a battery assembly. The battery assembly can be used to provide power to a vehicle such as an automobile. In such an environment, the battery assembly is connected to a load, such as a drive motor and a charging port, which can be connected to an electrical energy source. The battery assembly discharges to the drive motor to provide power to the vehicle and is charged through the charging port.

[0003] As the battery assembly cycles, that is, goes through periods of discharge to a load and charge through a charging port, heat is generated in the battery cells. If the battery cells are damaged, discharged too deeply, or improperly recharged, the heat generated can be significant, causing chemical reactions that ultimately lead to a thermal runaway condition. Thermal runaway is difficult to stop, so preventing thermal runaway is a design consideration when producing batteries. Therefore, it is desirable to provide a battery module with a system that limits the spread of heat through the battery assembly. Summary of the invention

[0004] According to a non-limiting example, a battery module includes a module housing including a plurality of walls defining an interior and a plurality of battery cells arranged in the interior. Each of the plurality of battery cells includes an exhaust port. An exhaust manifold is connected to each of the plurality of battery cells. The exhaust manifold includes a central channel fluidically connected to the exhaust port in each of the plurality of battery cells and a fluid inlet selectively allowing a certain amount of fluid to pass into a selected battery cell of the plurality of battery cells.

[0005] In addition to one or more features described herein, the exhaust manifold includes a first surface coupled to each of a plurality of battery cells, a second surface extending parallel to and spaced apart from the first surface, a first side surface, and a second side surface extending between and connected to the first surface and the second surface, wherein a fluid inlet is arranged in one of the first side surface and the second side surface.

[0006] In addition to one or more features described herein, a thermally responsive hatch is disposed above the fluid inlet.

[0007] In addition to one or more features described herein, the thermally responsive adhesive selectively couples the thermally responsive hatch to one of the first side surface and the second side surface.

[0008] In addition to one or more features described herein, the exhaust manifold includes a first hatch support disposed on one side of the fluid inlet and a second hatch support disposed on a second side of the fluid inlet, and the thermally responsive hatch is selectively supported between the first hatch support and the second hatch support closing the fluid inlet.

[0009] In addition to one or more features described herein, the exhaust manifold is formed of a thermally responsive material configured to expand when exposed to pressurized hot gas.

[0010] In addition to one or more features described herein, a fluid additive module is coupled to the exhaust manifold, the fluid additive module including a thermal runaway specific material selectively added to a quantity of fluid entering one of the plurality of battery cells through the exhaust module.

[0011] In addition to one or more features described herein, the fluid additive module is mounted on one of the first side surface and the second side surface above the fluid inlet.

[0012] In addition to one or more features described herein, a quantity of fluid is disposed within the interior of the module housing, and the fluid inlet selectively passes the quantity of fluid from the interior to flow through the vents of selected battery cells of the plurality of battery cells.

[0013] In addition to one or more features described herein, the exhaust manifold includes a first manifold portion coupled to each of the plurality of battery cells and a second manifold portion connected to the first manifold portion via a thermally responsive manifold joint, the fluid inlet being disposed at the thermally responsive joint.

[0014] According to a non-limiting example, a vehicle includes a body having a passenger compartment, a drive motor mounted in the body, and a rechargeable energy storage system including a battery assembly mounted to the body. The battery assembly includes a housing including a bottom wall and a plurality of side walls connected to the bottom wall. A plurality of battery modules are arranged in the housing. Each of the plurality of battery modules includes a module housing including a plurality of walls defining an interior. A plurality of battery cells are arranged in the interior. Each of the plurality of battery cells includes an exhaust port. An exhaust manifold is connected to each of the plurality of battery cells. The exhaust manifold includes a central channel fluidically connected to an exhaust port in each of the plurality of battery cells and a fluid inlet that selectively allows a certain amount of fluid to pass through a selected battery cell of the plurality of battery cells.

[0015] In addition to one or more features described herein, the exhaust manifold includes a first surface coupled to each of a plurality of battery cells, a second surface extending parallel to and spaced apart from the first surface, a first side surface, and a second side surface extending between and connected to the first surface and the second surface, wherein a fluid inlet is arranged in one of the first side surface and the second side surface.

[0016] In addition to one or more features described herein, a thermally responsive hatch is disposed above the fluid inlet.

[0017] In addition to one or more features described herein, the thermally responsive adhesive selectively couples the thermally responsive hatch to one of the first side surface and the second side surface.

[0018] In addition to one or more features described herein, the exhaust manifold includes a first hatch support disposed on one side of the fluid inlet and a second hatch support disposed on a second side of the fluid inlet, and the thermally responsive hatch is selectively supported between the first hatch support and the second hatch support closing the fluid inlet.

[0019] In addition to one or more features described herein, the exhaust manifold is formed of a thermally responsive material configured to expand when exposed to pressurized hot gas.

[0020] In addition to one or more features described herein, a fluid additive module is coupled to the exhaust manifold, the fluid additive module including an amount of heat absorbing material selectively added to an amount of fluid passing through the exhaust module into one of the plurality of battery cells.

[0021] In addition to one or more features described herein, the fluid additive module is mounted on one of the first side surface and the second side surface above the fluid inlet.

[0022] In addition to one or more features described herein, a quantity of fluid is disposed within the interior of the module housing, and the fluid inlet selectively passes the quantity of fluid from the interior to flow through the vents of selected battery cells of the plurality of battery cells.

[0023] In addition to one or more features described herein, the exhaust manifold includes a first manifold portion coupled to each of the plurality of battery cells and a second manifold portion connected to the first manifold portion via a thermally responsive manifold joint, the fluid inlet being disposed at the thermally responsive joint.

[0024] The above features and advantages and other features and advantages of the present disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a left side view of a vehicle including a battery assembly having a battery module including an exhaust manifold having a selectively activated fluid inlet according to a non-limiting example;

[0027] Figure 2 is a view of a battery assembly without a cover, showing a battery module, according to a non-limiting example;

[0028] Figure 3 According to non-limiting examples Figure 2 A perspective view of a battery module of a battery assembly showing an exhaust manifold;

[0029] Figure 4 According to non-limiting examples Figure 3 A side cross-sectional view of a battery module taken along line 4-4;

[0030] Figure 5A is a side cross-sectional view of an exhaust manifold prior to exhausting gases according to a non-limiting example;

[0031] Figure 5B is the exhaust gas according to a non-limiting example Figure 5A A side cross-sectional view of an exhaust manifold;

[0032] Figure 5C is according to a non-limiting example after exhausting the gas Figure 5B a side cross-sectional view of an exhaust manifold showing the selectively activated fluid inlet passageway being open to the fluid;

[0033] Fig. 6A is a side cross-sectional view of an exhaust manifold prior to exhausting gases according to another non-limiting example;

[0034] Figure 6B is the exhaust gas according to a non-limiting example Fig. 6A A side cross-sectional view of an exhaust manifold;

[0035] Figure 6C is according to a non-limiting example after exhausting the gas Figure 6B a side cross-sectional view of an exhaust manifold showing the selectively activated fluid inlet passageway being open to the fluid;

[0036] Figure 7 is a side cross-sectional view of an exhaust manifold according to another non-limiting example;

[0037] Figure 8 According to another non-limiting example Figure 2 A perspective view of a battery module of a battery assembly showing an exhaust manifold;

[0038] Fig. 9 According to non-limiting examples Figure 8 a side cross-sectional view of a battery module; and

[0039] Fig.10 According to yet another non-limiting example Figure 2 A side cross-sectional view of a battery module. DETAILED DESCRIPTION

[0040] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0041] According to a non-limiting example, the vehicle Figure 1 1. The vehicle 10 is generally indicated at 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20 having a seat 23 located behind an instrument panel 26. A steering controller 30 is disposed between the seat 23 and the instrument panel 26. The steering controller 30 is operated to control the orientation of selected wheels of the plurality of wheels 16. The vehicle 10 includes an electric drive motor 34 that provides power to one or more of the plurality of wheels 16.

[0042] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed within the vehicle body 12 and provides power to the electric drive motor 34. At this point, it should be appreciated that the location of the electric drive motor 34 and the battery assembly 38 may vary. Figure 2 , the battery assembly 38 includes a housing 48, which includes a bottom wall 52 and a plurality of side walls 54. The side walls 54 include a first side wall 58, a second side wall 59, a third side wall 60, and a fourth side wall 61 that together define an interior area 64. According to a non-limiting example, the housing 48 is shown to include a centerline 66. The centerline 66 extends between the third sidewall 60 and the fourth sidewall 61 and is equidistant from the first sidewall 58 and the second sidewall 59.

[0043] In a non-limiting example, the first plurality of battery modules 72 are disposed between the centerline 66 and the first side wall 58, and the second plurality of battery modules 74 are disposed between the centerline 66 and the second side wall 59. Figure 3 , and continue to refer to Figure 2 One of the first plurality of battery modules 72 is described, and it should be understood that the remaining battery modules in the first plurality of battery modules 72 and the second plurality of battery modules 74 include corresponding structures.

[0044] The battery module 72 includes a module housing 86 having a plurality of walls 88 defining an interior 90. In a non-limiting example, a plurality of battery cells 94 are arranged in the interior 90. Each of the plurality of battery cells 94 includes an outer surface 97 supporting an anode (not individually labeled), a cathode (also not individually labeled), and a vent 100. As will be described in detail herein, the vent 100 provides a passage that allows gases that may be generated in a respective one of the plurality of battery cells 94 to escape to the surrounding environment. A quantity of fluid 104 fills a portion of the module housing 86. In a non-limiting example, each of the plurality of battery cells 94 is completely immersed in the quantity of fluid 104.

[0045] In a non-limiting example, the exhaust manifold 106 extends through and is connected to the exterior surface 97 of each of the plurality of battery cells 94. Figure 4 And continue to refer to Figure 3 , the exhaust manifold 106 includes a central passage 108 that is fluidly connected to each exhaust port 100 of the plurality of battery cells 94. The central passage 108 is defined by a first surface 110 connected to each of the plurality of battery cells 94, a second surface 112 extending parallel to and spaced apart from the first surface 110, a first side surface 116, and a second side surface 118. The first side surface 116 and the second side surface 118 extend between and connect the first surface 110 and the second surface 112.

[0046] In a non-limiting example, a fluid inlet 124 is formed in the second side surface 118 of the exhaust manifold 106. As will be described in detail herein, the fluid inlet 124 selectively exposes the central channel 108 to a portion of the quantity of fluid 104 in the module housing 86. As will be described in detail herein, in the event of an overheating condition that causes gas generation in one of the plurality of battery cells 94, a portion of the quantity of fluid 104 can flow into the one of the plurality of battery cells after the gas is exhausted to initiate a cooling process.

[0047] In a non-limiting example, the thermally responsive hatch 128 is mounted above the fluid inlet 124, such as Figure 5A As shown. In one non-limiting example, the thermally responsive hatch 128 can be formed of a thermally responsive material, such as a material that will shrink, melt, or otherwise change geometry when exposed to a selected temperature. In another non-limiting example, the thermally responsive hatch 128 can be secured to the second side surface 118 with a thermally responsive material 130 that ceases to maintain bonding properties when exposed to a selected temperature. In yet another non-limiting example, when gas at a selected temperature fills the central passage 108, a mechanism (not shown) can move the thermally responsive hatch 128 to expose the fluid inlet 124.

[0048] In a non-limiting example, in the event of a thermal runaway condition in one of the plurality of battery cells 94, high pressure, high temperature gas will be generated. At this point, it should be understood that high temperature, high pressure gas refers to gas having a temperature exceeding 1000°C and a pressure exceeding 150 kPa. The high temperature, high pressure gas will force the exhaust port 100 associated with one of the plurality of battery cells 94 to open and be discharged into the exhaust manifold 106, as shown in FIG. Figure 5B As shown. When high temperature and high pressure gas flows through the exhaust manifold 106 to, for example, the surrounding environment, the thermal response hatch 148 is activated. When present in the central passage 108, the high temperature and high pressure gas keeps the thermal response hatch 128 closed.

[0049] Once the high temperature and high pressure gas dissipates, the thermally responsive hatch 128 opens the fluid inlet 124, such as Figure 5C As shown, a portion of the volume of fluid 104 is allowed to flow into the exhaust manifold 106, through the exhaust port 100, and into one of the plurality of battery cells 94 that is experiencing thermal runaway. This portion of the volume of fluid will reduce the temperature, thereby reducing the likelihood that the thermal runaway will spread to additional battery cells in the plurality of battery cells 94.

[0050] exist Fig. 6A In the non-limiting example shown, the exhaust manifold 106 is formed of a thermally responsive material that can change geometry when exposed to a selected temperature and / or pressure. The exhaust manifold 106 can include a first hatch support 142 and a second hatch support 144 disposed adjacent to the fluid inlet 124. The thermally responsive hatch 128 is supported between the first hatch support 142 and the second hatch support 144. In the event that a thermal runaway condition exists in one of the plurality of battery cells 94, high pressure and high temperature gases will be generated. The high temperature and high pressure gases will force the exhaust port 100 associated with one of the plurality of battery cells 94 to open and discharge into the exhaust manifold 106, as shown in FIG. Figure 6B As shown, the exhaust manifold 106 is deformed.

[0051] The deformation of the exhaust manifold 106 causes the first hatch support 142 and the second hatch support 144 to stop applying pressure to the thermal responsive hatch 128. When present in the central passage 108, the high temperature and high pressure gas keeps the thermal responsive hatch 128 closed. Once the high temperature and high pressure gas dissipates, the thermal responsive hatch 128 opens the fluid inlet 124, such as Figure 6C As shown, a portion of the volume of fluid 104 is allowed to flow into the exhaust manifold 106, through the exhaust port 100, and into one of the plurality of battery cells 94 that is experiencing thermal runaway. This portion of the volume of fluid will reduce the temperature, thereby reducing the likelihood that the thermal runaway will spread to additional battery cells in the plurality of battery cells 94.

[0052] Now refer to Figure 7 An exhaust manifold 156 according to another non-limiting example is described. The exhaust manifold 156 includes a first manifold portion 160 connected to the outer surface 97 of each of the plurality of battery cells 94 and a second manifold portion 162 connected to the first manifold portion 160 by a thermally responsive seam 166. A flange 170 surrounds the first manifold portion 160. A flange retainer 172 surrounds the second manifold portion 162. The flange retainer 172 includes a lip (not separately labeled) that captures the flange 170. A thermally responsive adhesive 174 bonds the flange 170 to the flange retainer 172, forming a thermally responsive manifold seam 166.

[0053] In a non-limiting example, in the event of a thermal runaway condition in one of the plurality of battery cells 94, high-pressure, high-temperature gas will be generated. The high-temperature, high-pressure gas will force the vent 100 associated with one of the plurality of battery cells 94 to open and vent into the exhaust manifold 156. The gas will flow through the exhaust manifold 156, causing the thermally responsive adhesive 174 to fail.

[0054] The high pressure and high temperature gases force the second manifold portion 162 away from the first manifold portion 160. However, the second manifold portion 162 is held in place by the interaction between the flange retainer 172 and the flange 170. Once the gases dissipate, the second manifold portion 162 relaxes, opening the thermally responsive seam 166, allowing fluid to pass through the exhaust manifold 156 into one of the plurality of battery cells 94. In a manner similar to that described herein, this portion of the volume of fluid 104 will reduce the temperature, thereby reducing the likelihood of thermal runaway.

[0055] Now refer to Figure 8 and Fig. 9 A fluid additive module 190 is depicted coupled to the second side surface 118 of the exhaust manifold 106. The fluid additive module 190 is fluidly coupled to the fluid inlet 124. In a non-limiting example, once the thermal responsive hatch 128 is released and opened, a quantity of thermal runaway (TR) specific material 192, which may be in various forms including liquid, solid, semi-solid, etc., flows into the central passage 108. The thermal runaway specific material may take the form of a heat absorbing material, an inert gas generating material, an oxygen absorbing material, etc. The release of the thermal runaway specific material 192 or the opening of the hatch 128 allows the fluid 104 to pass through a one-way valve 194 in the fluid additive module 190. A portion of the quantity of fluid flows through the additive module 190, carrying the thermal runaway specific material 192 into the central passage 108.

[0056] The portion of the quantity of fluid 104 passes through the exhaust manifold 106, carrying the thermal runaway specific material 192 into one of the plurality of battery cells 94 that is experiencing thermal runaway. In a manner similar to that described herein, adding the thermal runaway specific material 192 to a portion of the quantity of fluid 104 further enhances the fluid's ability to absorb heat to reduce the temperature, thereby reducing the likelihood that thermal runaway will propagate to additional battery cells in the plurality of battery cells 94. For example, the thermal runaway specific material 192 may quickly bring the temperature of one of the plurality of battery cells 94 to below 600°C. At this point, it should be understood that the location of the fluid additive module 190 may vary. As Fig.10 As shown, the fluid additive module 190 may be disposed between the first surface 110 of the exhaust manifold 106 and the exterior surfaces 97 of the plurality of battery cells 94 .

[0057] At this point, it should be understood that while the battery cells are shown as immersed in cooling fluid in the battery module, a certain amount of fluid entering the exhaust manifold can originate from external sources, including fluid introduced by first responders, fluid introduced from other fluid retaining elements, etc., in order to reduce battery cell temperature and mitigate thermal runaway conditions.

[0058] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced items. The term "or" means "and / or", unless the context clearly indicates otherwise. References to "an aspect" throughout the specification mean that a particular element (e.g., feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in various aspects.

[0059] When an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

[0060] Unless otherwise indicated herein, all test standards are the most recent standards in effect as of the filing date of the present application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0061] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0062] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from the scope thereof. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the disclosure without departing from the essential scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery module, comprising: a module housing including a plurality of walls defining an interior; a plurality of battery cells disposed in the interior, each of the plurality of battery cells including a vent; as well as An exhaust manifold is connected to each of the plurality of battery cells, the exhaust manifold including a central passage fluidly connected to an exhaust port in each of the plurality of battery cells and a fluid inlet selectively allowing a certain amount of fluid to pass into a selected battery cell of the plurality of battery cells.

2. The battery module according to claim 1, wherein: The exhaust manifold includes a first surface coupled to each of the plurality of battery cells, a second surface extending parallel to and spaced apart from the first surface, a first side surface, and a second side surface extending between and connected to the first and second surfaces, the fluid inlet being arranged in one of the first and second side surfaces.

3. The battery module of claim 2, further comprising a thermally responsive hatch disposed above the fluid inlet. 4 . The battery module of claim 3 , further comprising a thermally responsive adhesive selectively coupling the thermally responsive hatch to one of the first and second side surfaces.

5. The battery module according to claim 3, wherein: The exhaust manifold includes a first hatch support disposed on one side of the fluid inlet and a second hatch support disposed on a second side of the fluid inlet, the thermally responsive hatch being selectively supported between the first hatch support and the second hatch support closing the fluid inlet.

6. The battery module according to claim 5, wherein: The exhaust manifold is formed from a thermally responsive material configured to expand when exposed to pressurized hot gas.

7. The battery module of claim 2, further comprising a fluid additive module connected to the exhaust manifold, the fluid additive module comprising a thermal runaway specific material selectively added to the amount of fluid entering one of the plurality of battery cells through the exhaust manifold.

8. The battery module of claim 1, further comprising a volume of fluid disposed in an interior of the module housing, the fluid inlet selectively allowing a portion of the volume of fluid from the interior to flow through a vent of a selected battery cell among the plurality of battery cells.

9. The battery module according to claim 1, wherein: The exhaust manifold includes a first manifold portion coupled to each of the plurality of battery cells and a second manifold portion connected to the first manifold portion via a thermally responsive manifold joint, the fluid inlet being disposed at the thermally responsive manifold joint.

10. A vehicle comprising: The body of the vehicle including the passenger compartment; a drive motor mounted in the vehicle body; as well as A rechargeable energy storage system comprising a battery assembly mounted to a vehicle body, the battery assembly including the battery module of claim 1.

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