Battery pack housing with thermally conductive plate

Abstract

The battery pack includes: a case including interconnected walls; the one or more battery units are accommodated in the shell; and a thermally conductive plate that defines one or more of the interconnected walls and that is structurally load-bearing. The heat conduction plate is provided with a first section and a second section, wherein the one or more battery units are in heat exchange relation with the first section; and a second section in heat exchange relationship with the first section. The second section is in a heat exchange relationship with an environment external to the housing to provide heat exchange between the one or more battery cells and the environment.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 63 / 366,850, filed on June 23, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to batteries and, more particularly, to heat transfer devices operable to remove heat from or provide heat to such batteries. Background Art

[0004] Electric vehicles and other types of electrical equipment may be powered by one or more batteries. Each battery typically includes multiple cells that are operatively connected to each other. Batteries generate heat when power is drawn from them and when power is provided to them (e.g., during charging). In some cases, operating a battery when the temperature of the battery exceeds a maximum temperature threshold may hinder its performance and, in some cases, may damage the battery. Hot ambient temperatures may also contribute to an increase in battery temperature. In addition, when a battery is operated at a temperature below a minimum temperature threshold, the performance of the battery may decrease. Although attempts have been made to better regulate the temperature of batteries, improvements are still being sought. Summary of the invention

[0005] Therefore, a battery pack is provided, which includes: a shell containing interconnecting walls; one or more battery cells, which are accommodated in the shell; and a heat conductive plate, which defines one or more of the interconnecting walls and is structurally load-bearing, the heat conductive plate having a first section and a second section, the one or more battery cells are in a heat exchange relationship with the first section, the second section is in a heat exchange relationship with the first section, and the second section is in a heat exchange relationship with the environment outside the shell to provide heat exchange between the one or more battery cells and the environment.

[0006] In certain embodiments, the battery pack as defined above and described herein further comprises one or more of the following features in whole or in part and in any combination.

[0007] In certain aspects, the one or more battery cells are secured to the first section of the thermally conductive plate.

[0008] In certain aspects, the first segment and the second segment extend transversely to each other and each define a respective side of the housing.

[0009] In certain aspects, the first section includes a first plate and the second section includes a second plate, the thermally conductive plate includes heat pipes mounted to both the first plate and the second plate, wherein the heat pipes extend from a first end on the first plate to a second end on the second plate.

[0010] In certain aspects, the second plate has an inner side facing the one or more battery cells and an outer side opposite the inner side, the outer side defining fins.

[0011] In certain aspects, the first plate and the second plate define a groove, and the heat pipe is received within the groove.

[0012] In certain aspects, the first plate and the second plate are made of a material having a thermal conductivity of at least 10 W / mK.

[0013] In certain aspects, the thermally conductive plate includes: a first shell and a second shell defining a cavity therebetween; a core assembly having a wicking layer adjacent to an inner side of the first shell, and a steam core, the wicking layer and the steam core being received within the cavity; and a working fluid within the cavity.

[0014] In certain aspects, one or more coolant conduits are embedded within the second section, the coolant conduits providing for the flow of coolant and being in fluid communication with a cooling system for extracting heat from the coolant.

[0015] In certain aspects, the second section surrounds one or more coolant pipes through which coolant flows and which are in fluid communication with a cooling system for extracting heat from the coolant.

[0016] In certain aspects, fins protrude from the second section of the thermally conductive plate.

[0017] In some aspects, the battery pack includes a third section, the first section and the third section are connected together via the second section, the first section, the second section and the third section define a U-shape, and the one or more battery cells are located between the first section and the third section.

[0018] In certain aspects, the first segment includes four lateral segments that each extend generally laterally from a respective edge of the second segment, the four lateral segments and the second segment defining the housing.

[0019] In certain aspects, a battery support is secured to the first section, the battery support defining a plurality of cell engagement tabs, each cell engagement tab defining a cavity that receives a respective one of the one or more battery cells.

[0020] An electric vehicle is also provided, comprising: a chassis including a frame having frame components; and a battery pack fixed to the frame, the battery pack having: a shell including interconnecting walls; one or more battery cells accommodated in the shell; and a heat conductive plate defining one or more of the interconnecting walls and structurally load-bearing, and configured to increase the rigidity of the frame, the heat conductive plate having a first section and a second section, the one or more battery cells being in a heat exchange relationship with the first section, the second section being in a heat exchange relationship with the first section, and the second section being in a heat exchange relationship with an environment outside the shell to provide heat exchange between the one or more battery cells and the environment.

[0021] In certain embodiments, the electric vehicle as defined above and described herein further comprises one or more of the following features in whole or in part and in any combination.

[0022] In certain aspects, one of the frame members is secured to another of the frame members via the thermally conductive plate.

[0023] In certain aspects, the thermally conductive plate has a bottom surface that is exposed to an environment external to the electric vehicle.

[0024] In certain aspects, the stiffness of the frame is increased by at least 10% by the thermally conductive plate.

[0025] In certain aspects, the electric vehicle includes a bracket via which the thermally conductive plate is secured to the frame member.

[0026] In certain aspects, a load path extends from the frame member to the thermally conductive plate via the bracket, the bracket being configured to support the weight of a battery pack.

[0027] In some aspects, the thermally conductive plate is configured to support the weight of the one or more battery cells.

[0028] On the other hand, a battery pack is provided, comprising: a shell including interconnecting walls; one or more battery cells accommodated in the shell; and a heat conductive plate defining one or more of the interconnecting walls and bearing structural load, the heat conductive plate having a first section and a second section, the one or more battery cells being in a heat exchange relationship with the first section, the second section being in a heat exchange relationship with the first section, and the second section being in a heat exchange relationship with an environment outside the shell to discharge heat from the one or more battery cells.

[0029] The battery pack described above may include any of the following features in any combination.

[0030] In some embodiments, the one or more battery cells are secured to the first section of the thermally conductive plate.

[0031] In some embodiments, the first segment and the second segment extend transversely to each other and each define a respective side of the housing.

[0032] In some embodiments, the first section includes a first plate and the second section includes a second plate, the thermally conductive plate includes heat pipes mounted to both the first plate and the second plate, wherein the heat pipes extend from a first end on the first plate to a second end on the second plate.

[0033] In some embodiments, the second plate has an inner side facing the one or more battery cells and an outer side opposite the inner side, the outer side defining fins.

[0034] In some embodiments, the first plate and the second plate define a groove, and the heat pipe is received in the groove.

[0035] In some embodiments, the first plate and the second plate have a thickness of at least 1 mm.

[0036] In some embodiments, the first plate and the second plate are made of a material having a thermal conductivity of at least 10 W / mK.

[0037] In some embodiments, the thermally conductive plate includes: a first shell and a second shell defining a cavity therebetween; a core assembly having a wicking layer adjacent to an inner side of the first shell, and a steam core, the wicking layer and the steam core being received in the cavity; and a working fluid in the cavity.

[0038] In some embodiments, one or more coolant conduits are embedded within the second section, the coolant conduits providing for the flow of coolant and being in fluid communication with a cooling system for extracting heat from the coolant.

[0039] In some embodiments, the second section encloses the one or more coolant conduits through which coolant flows and which are in fluid communication with a cooling system for extracting heat from the coolant.

[0040] In some embodiments, fins protrude from the second section of the thermally conductive plate.

[0041] In some embodiments, the first segment and the third segment are connected together via the second segment, the first segment, the second segment and the third segment define a U-shape, and the one or more battery cells are located between the first segment and the third segment.

[0042] In some embodiments, the first segment includes four lateral segments that each extend generally laterally from a respective edge of the second segment, the four lateral segments and the second segment defining the housing.

[0043] In some embodiments, a battery support is secured to the first section.

[0044] In some embodiments, the battery support defines a plurality of cell engagement protrusions, each cell engagement protrusion defining a cavity for a respective one of the one or more battery cells.

[0045] In some embodiments, a controller is operatively connected to the one or more battery cells, the controller being in a heat exchange relationship with the first segment. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Reference is now made to the accompanying drawings, in which:

[0047] Figure 1 is a three-dimensional view of a battery pack according to one embodiment;

[0048] Figure 2 yes Figure 1 3D exploded view of the battery pack;

[0049] Figure 3 yes Figure 1 A three-dimensional view of a heat conducting plate of a battery housing of a battery pack;

[0050] Figure 4 is a side view of a portion of a heat conducting plate showing fins of the heat conducting plate;

[0051] Figure 5 is a three-dimensional view of a housing of a battery pack according to another embodiment;

[0052] Figure 6 According to another embodiment, Figure 5 A three-dimensional partial cross-sectional view of a heat conducting plate of a shell;

[0053] Figure 7 yes Figure 6 A schematic cross-sectional view of a layered structure of a heat conducting plate;

[0054] Figure 8 It shows the heat exchange process Figure 6 A schematic cross-sectional view of a heat conducting plate;

[0055] Fig. 9 is connected to a coolant pipe according to one embodiment Figure 5 3D view of the heat conducting plate;

[0056] Fig.10 is along Fig. 9 A cross-sectional view taken along line II on FIG.

[0057] Fig.11 According to another embodiment, the coolant pipe is connected Figure 5 3D view of the heat conducting plate;

[0058] Fig.12 According to another embodiment, a coolant pipe is connected Figure 5 3D view of the heat conducting plate;

[0059] Fig.13 Connected to the fin Figure 5 3D view of the heat conducting plate;

[0060] Fig.14 According to another embodiment, a coolant pipe is connected Figure 5 3D view of the heat conducting plate;

[0061] Fig.15 is a three-dimensional view of a battery pack having a battery cell partially enclosed by a thermally conductive plate according to another embodiment;

[0062] Fig.16 is a three-dimensional view of a heat conducting plate according to another embodiment;

[0063] Fig.17 is a three-dimensional view of a housing with a heat conducting plate according to yet another embodiment;

[0064] Fig.18 is a three-dimensional view of a heat conducting plate according to another embodiment;

[0065] Fig.19 According to one embodiment, the battery support is connected Figure 5 3D view of the heat conducting plate;

[0066] Fig. 20 is where the battery cell is fixed to Fig.19 A side view of a battery support; and

[0067] Fig.21 Is equipped with Figure 1-20 A schematic top view of a vehicle with any one of the battery packs. DETAILED DESCRIPTION

[0068] refer to Figure 1-2, a battery pack (or battery "module") is shown at 1 and includes one or more battery cells 2, a controller 3 (also known as a battery management system (BMS)) operatively connected to the one or more battery cells 2, a support 4 for fixing the one or more battery cells 2 together, and a connector 5 operatively connected to the controller 3 and the one or more battery cells 2. The connector 5 can be used as an interface to connect the battery pack 1 to a device requiring power, such as an electric vehicle. The battery cell 2 is depicted here as being cylindrical. However, other shapes of battery cells are contemplated, such as prismatic or pouch-shaped. An electric vehicle may include a battery pack having a plurality of modules combined together, the plurality of modules being connected in parallel to simply increase storage capacity, or in series to increase voltage. Each of these modules may include a plurality of battery cells.

[0069] More specifically refer to Figure 2 , the battery pack 1 includes a housing 6, the size of which is designed to accommodate one or more battery cells 2, a controller 3 and a support 4. The housing 6 is provided herein in the form of a rectangular prism having six sides. The housing 6 includes a main casing 7 having a plurality of interconnected side walls 8, which define multiple (e.g., 3, 4 or more) of the six sides of the housing 6. In some embodiments, the main casing 7 may define any number of sides of the housing 6. The heat conducting plate 10 defines at least some or all of the remaining sides of the housing 6. It should be understood that the housing 6 may have any suitable shape, and the main casing 7 and the heat conducting plate 10 cooperate with each other to define the sides of the housing 6. The main casing 7 may define any number of sides of the housing 6, and the heat conducting plate 10 may define at least a portion of the remaining sides of the housing 6.

[0070] Thus, the thermally conductive plate 10 may have two functions: 1) the thermally conductive plate structurally defines a portion of the housing 6; and 2) the thermally conductive plate provides a heat transfer relationship between one or more battery cells 2 and the environment outside the housing 6. Thus, the thermally conductive plate 10 is constructed of a material having sufficient rigidity to withstand the loads applied to the battery pack 1 during use. In the illustrated embodiment, the electronics of the battery pack 1 may be secured to the thermally conductive plate 10. This may allow the electronics and microprocessor to be cooled similarly to the battery cells by contact with the thermally conductive plate 10. In other words, in the illustrated embodiment, the controller 3 may be in heat transfer relationship (e.g., thermal contact) with the thermally conductive plate 10 to be cooled thereby.

[0071] Reference now Figure 3, the heat conductive plate 10 is described in more detail. In the illustrated embodiment, the heat conductive plate 10 includes a first section 11 and a second section 12, the second section being fixed to the first section 11 and extending generally transversely to the first section 11. In the present embodiment, the first section 11 and the second section 12 include a first plate 13 and a second plate 14, respectively. The first plate 13 and the second plate 14 may be made of aluminum or any other suitable material having both sufficient rigidity to provide the required structural integrity to the battery pack 1 and sufficient thermal conductivity to be able to transfer heat from one or more battery cells 2, as will be further described below. The material of the plates 13, 14 may have a thermal conductivity of at least 10 W / mK. In some embodiments, the thermal conductivity of the material of the plates 13, 14 is at least 100 W / mK, preferably about 200 W / mK. The first plate 13 and the second plate 14 may be structurally load-bearing.

[0072] In the context of the present disclosure, the expression "structurally load-bearing" means that the first plate 13 and the second plate 14 are capable of withstanding the loads applied to the battery pack 1 during use. For example, the loads may be acceleration / deceleration forces, torsional forces applied by the vehicle frame to which the battery pack 1 is fixed, bending forces applied by the frame, the weight of the battery cells 2, and the like. If the wall or plate maintains its shape under the application of these loads during normal use of the battery pack 1, the wall or plate can be considered to be load-bearing. If, although the plate or wall may exhibit some deformation, these deformations remain within the elastic deformation range of the plate or wall and are not permanent, the wall or plate can be considered to have maintained its shape. These deformations do not impair the operation of the battery pack 1. For example, thermal contact may be required between the battery cell and the thermally conductive plate 10. When a flexible thermal interface material (TIM) is used between the battery cell and the thermally conductive plate 10, some deformation may be acceptable. The TIM is typically a paste or a flexible film that can provide up to about 100 microns. The stiffness of the thermally conductive plate is selected to be sufficient to keep the deformation below this value when subjected to mechanical loads. The expression "structurally load-bearing" may mean that the plates 13, 14 or another component can withstand bending forces, and / or withstand torsion forces, and / or withstand shear forces. The expression "withstand" means that the deformation of the plates 13, 14 remains within the elastic range when subjected to bending forces, torsion forces or shear forces.

[0073] The structural nature of the thermally conductive plate 10 may in some cases permit the elimination of other components that would otherwise be required for a typical non-structural counterpart. For example, in addition to being used for heat transfer, the thermally conductive plate 10 may also be used to structurally interconnect two different components of a vehicle or another system.

[0074] Thus, in addition to its thermal management function, the thermally conductive plate 10 described above and any thermally conductive plate described herein may be used as a casing portion of a battery module. Thus, this may allow for the removal of components. The thermally conductive plate may form the bottom casing of the battery module and is configured to support the weight of the cells and protect the components of the battery module (e.g., cells, electronics, etc.) from forces applied to the frame of the vehicle, for example, during normal use of the vehicle. Fig.21 Provide more details on this aspect.

[0075] The first plate 13 may be integrally integrated with the second plate 14 as a single part. The angle between the first plate 13 and the second plate 14 may be created by bending a flat plate, by casting, or by machining. The first plate 13 may be fixed to the second plate 14 by brazing or welding. In some embodiments, a bracket may be used to fix the first plate 13 to the second plate 14. The first plate 13 may be fastened to the second plate 14.

[0076] The first plate 13 defines a first groove 13A, and the second plate 14 defines a second groove 14A. The first groove 13A and the second groove 14A are connected to each other and are sized to receive a heat pipe 15 extending longitudinally along both the first plate 13 and the second plate 14. More specifically, each heat pipe 15 has a section overlapping with the first plate 13 and a second section overlapping with the second plate 14. Therefore, the heat pipe 15 can define an elbow 15A to follow the corner defined at the intersection of the first plate 13 and the second plate 14. The heat pipe 15 can be any suitable heat pipe. The heat pipe 15 can transfer heat by a phase change (e.g., from a liquid state to a gaseous state, and vice versa) of a fluid contained in the heat pipe 15. The heat pipe 15 can be adhered to the first groove 13A and the second groove 14A using, for example, a heat transfer adhesive, a glue (e.g., an epoxy resin), a mechanical fastener, or by metal brazing.

[0077] Reference now Figure 4 The second section 12 further defines a fin 14B fixed to the outer side of the second plate 14; the outer side faces away from the one or more battery cells 2. The fin 14B extends in a direction substantially normal to the second plate 14 and away from the second plate. The fin 14B extends substantially transversely to the heat pipe 15. Figure 4 In the embodiment of the present invention, the fins 14B extend longitudinally and parallel to the first plate 13. Alternatively, the fins 14B may extend vertically and perpendicular to the first plate 13. The fins 14B may extend at any suitable angle. Extending the fins 14B parallel to the first plate 31 may allow the fins 14B to receive heat from the heat pipes 15 at multiple locations along the length of their bases. The heat from the heat pipes 15 may be transferred to the second plate 14 by conduction, from the second plate 14 to the fins 14B by conduction, and from the fins 14B to the environment outside the housing 6 by convection.

[0078] The thickness T1 of the first plate 13 may be about 1 mm to about 5 mm. The thickness T2 of the second plate 14 may be about 1 mm to about 5 mm. The first plate 13 and the second plate 14 may be made of aluminum or any other suitable material such as stainless steel.

[0079] Reference now Figure 5 , shown at 16 for Figure 1 Another embodiment of the housing of the battery pack 1 of the embodiment of the present invention. The housing 16 includes four interconnected side walls and a heat conductive plate 30. The interconnected side walls include a top plate 17A, a first side plate 17B, a second side plate 17C opposite the first side plate 17B, and a first end plate 17D. The heat conductive plate 30 defines a bottom plate 17E and a second end plate 17F of the housing 16 opposite the first end plate 17D. The plates 17A, ..., 17F of the housing 16 are interconnected with each other using any suitable means to enclose a size suitable for receiving one or more battery cells 2 ( Figure 1 The plates 17A, ..., 17F may be sealingly engaged with each other to protect the battery cells 2 housed in the housing 16 from water or other debris.

[0080] Reference Figure 6 , another embodiment of a heat conductive plate is shown at 30. The heat conductive plate 30 includes a first section 31 and a second section 32 that is generally transverse to the first section 31, such that the heat conductive plate 30 has an L-shape. The two sections 31, 32 of the heat conductive plate 30 can be structurally load-bearing, as defined above. In addition, the load-bearing properties of the heat conductive plate 30 can allow the heat conductive plate 30 to resist forces that cause the two sections 31, 32 to rotate relative to each other. The first section 31 can define the bottom plate 17E of the housing 16, and the second section 32 can define the second end plate 17F of the housing 16. The first section 31 can be connected to one or more battery cells 2( Figure 2 ) contact. In other words, the first section 31 is in heat exchange relationship with one or more battery cells 2. Figure 6 The heat conductive plate 30 depicted in FIG. 1 has a bend therein to form its L-shape, but it should be understood that the heat conductive plate 30 described herein may also be a flat (i.e., non-bent) plate. More details regarding the heat conductive plate 30 are presented in U.S. Patent Application No. 63 / 290,752, the entire contents of which are incorporated herein by reference. The battery cells 2 may be directly bonded to the heat conductive plate 30. Thus, the heat conductive plate 30 may serve as an electrical bus bar. For Figure 1 This can also be the case for the heat conducting plate 10 .

[0081] More specifically refer to Figure 7, the heat conducting plate 30 has a layered structure 100. The layered structure 100 includes an outer envelope or shell consisting of a first shell portion 101 and a second shell portion 102 (hereinafter referred to as the first shell 101 and the second shell 102). A cavity 103 is defined between the first shell 101 and the second shell 102. The first shell 101 is connected to the second shell 102 along the periphery of the heat conducting plate 30. More specifically, along the complete and uninterrupted periphery of the first shell 101 and the second shell 102, the first peripheral flange of the first shell 101 is butted and fixed to the second peripheral flange of the second shell 102 in a sealing manner. In some embodiments, the periphery can be interrupted by a filling tube, which can be used to evacuate the cavity 103, inject water into the interior, and then seal to maintain a partial vacuum inside. This filling tube can be positioned along the periphery seal between the flanges. The first shell 101 is connected to the second shell 102 via the first and second peripheral flanges or peripheries. In another embodiment, water is first injected and the two plates are secured into a low pressure environment, as described, for example, in International Patent Application No. PCT / CA2022 / 051825, the entire contents of which are incorporated herein by reference.

[0082] The structural load-bearing capacity of the thermally conductive plate 30 may be provided by one or more of the first and second shells 101, 102. In other words, the first and / or second shells 101, 102 may have a thickness of at least about 1 mm to about 5 mm and may be made of aluminum or steel or any other material that enables the plate to be structurally load-bearing. It should be understood that the thickness may be selected based on the structural characteristics and thermal properties (e.g., thermal conductivity) of the materials used. In some embodiments, at least a portion of the load-bearing capacity of the thermally conductive plate 30 may be provided by securing the two flanges of the first and second shells 101, 102 to each other and providing an effective thickness corresponding to the thickness of the flange of the first shell 101 plus the thickness of the flange of the second shell 102.

[0083] In the cavity 103 defined in the outer shell formed by the first shell 101 and the second shell 102, the heat conductive plate 30 also includes a core assembly, which includes a first wicking layer 104 and a second wicking layer 105. The first wicking layer 104 is disposed adjacent to the first shell 101. The second wicking layer 105 is disposed adjacent to the second shell 102. The core assembly further includes a steam core 106 disposed between the first wicking layer 104 and the second wicking layer 105. Therefore, the sandwiched core assembly fills the cavity 103 defined between the inner surfaces of the walls of the first shell and the second shell 102, and the sandwiched core assembly is composed of the first wicking layer 104, the steam core 106 and the second wicking layer 105. In an alternative embodiment, only one wicking layer may be used, so that the core assembly includes a steam core and a wicking layer. The wicking layer may preferably be positioned on the inner wall of the shell in contact with the battery cell so that the liquid in the wicking layer can evaporate to absorb the heat generated by the battery cell. The portion of the casing that contacts and faces the battery cell may be thinner to facilitate heat transfer across the casing. Additionally, the opposing casing facing away from the battery cell may be thicker to withstand mechanical loads, provide structural support, and increase the thermal resistance between the cell and the environment to limit heat loss from the cell at low temperatures (e.g., winter).

[0084] Reference Figure 8 , having described the different components of the heat conducting plate 30 above, the operation of the heat conducting plate 30 will now be described.

[0085] The heat conducting plate 30 has a first end 30A, which can be in contact with one or more battery cells 2 to receive heat therefrom. The second end 30B can be in contact with a heat sink or a cold plate to extract heat. The heat conducting plate 30 is operable to move heat from the first end 30A to the second end 30B. For this purpose, the working fluid is present in the first wicking layer 104 and the second wicking layer 105 in liquid form. When exposed to heat, the working fluid evaporates in the gas phase and migrates along arrow A1 into the cavity 103 containing the steam core 106. The working fluid in the gas phase then migrates along arrow A2 along the steam core 106 toward the second end 30B of the heat conducting plate 30. Since the second end 30B is colder than the first end 30A, the working fluid condenses back to the liquid phase and is absorbed by the first wicking layer 104 and the second wicking layer 105 along arrow A3. Subsequently, the working fluid moves along the first wicking layer 104 and the second wicking layer 105 by capillary action, and migrates back toward the first end 30A along arrow A4, and the process starts again. The thermally conductive plate 30 thus removes heat from the first end 30A by evaporating the working fluid, and transfers heat to the second end 30B by condensing the working fluid. These phase changes cause heat to move from the first end 30A to the second end 30B. In applications where components (i.e., batteries) must be heated rather than cooled, the reverse behavior and direction of the liquid and vapor flows are reversed without any changes to the plate structure.

[0086] Reference now Figure 9-10 In the illustrated embodiment, the second section 32 of the heat conducting plate 30 can be operatively connected to the cooling system 110. More specifically, a plurality of pipes 111 extend through the second section 32 of the heat conducting plate 30. A plurality of pipes 111 can be received between the two wicking layers 104, 105 and disposed in the cavity 106. The pipes 111 are fluidly connected to the cooling system 110 and are provided for a coolant (e.g., a liquid coolant) to flow in and out of the second section 32. In other words, the coolant can flow from the cooling system 110 in the pipes 111 and reach the second section 32 of the heat conducting plate 30, wherein the heat of the second section 32 is transferred to the coolant. Then, the coolant flows out of the second section 32 via the pipes 111 and reaches the cooling system 110, where heat can be extracted from the coolant. In some embodiments, the cooling system 110 may include a heat exchanger having a first pipe fluidly connected to the pipes 111 and a second pipe in heat exchange relationship with the first pipe. The second conduit may be in heat exchange relationship with a medium at a lower temperature (e.g., ambient air). In the present embodiment, conduit 111 comprises three conduits, but more or less than three conduits may be used. Conduits 111 may be parallel to each other and extend substantially transversely relative to first section 31. Other configurations are contemplated.

[0087] Integrating flow channels into a heat conducting plate may be challenging, as the plate may need to be hermetically sealed. Alternatively, the flow channels may be against the outer wall. The flow channels may then be outside the cavity of the heat conducting plate and may directly contact the outer wall or be integrally manufactured as part of one or both of the outer walls. Alternatively, the channels may be defined in the plate, and the plate may be attached to the outer wall of the heat conducting plate. If the outer wall is thick enough, the channels may be formed directly in the outer wall.

[0088] Alternatively, the cooling system 110 may include a heat pump 112, wherein the coolant changes from a liquid phase to a gas phase within the second section 32, and then the heat pump acts as an evaporator. The coolant in its gas phase then flows through a compressor and then through a condenser, where the coolant changes from a gas phase to a liquid phase. The coolant is expanded by an expansion valve to return to the gas phase, becomes colder and returns to the second section 32 via a pipe 111.

[0089] refer to Fig.11 In the illustrated embodiment, a plurality of conduits 211 extend within the second section 32 of the heat conducting plate 30. In the present case, each conduit 211 defines a U-shape within the second section 32 of the heat conducting plate 30. These conduits 211 may be in fluid flow communication with the cooling system 110 / heat pump 112 described above. Fig.12In this embodiment, the second section 32 of the heat conducting plate 30 encloses a pipe 311 for coolant flow. The pipe 311 can be fluidly connected to the cooling system 110 / heat pump 112 described above. Fig.13 In the illustrated embodiment, the fins 411 protrude from the second section 32 of the heat conducting plate 30. The fins 411 may extend from both sides of the heat conducting plate 30: toward and away from the battery cell 2 ( Figure 2 ) extends. The cooling air flow can absorb heat from the fins 411 via convection. Although shown with bends, alternatively, the heat conducting plate 30 can be straight, with fins protruding above and below, or protruding on only one side.

[0090] Reference Fig.14 , a heat conducting plate according to another embodiment is shown at 130. The heat conducting plate 130 may define one side wall of the housing of the battery pack as previously discussed. The heat conducting plate 130 has two sections 131, 132 that may be coplanar. That is, the two sections 131, 132 may be parallel to each other. As shown in other embodiments, the two sections may also be at a 90 degree angle to each other. The pipe 511 may be embedded in the second section 132. The pipe 511 may be located at the steam core 106 ( Figure 7 ) extends in the second section 132 of the heat conducting plate 130. The diameter of the conduit 511 may be greater than the thickness of the second section 132 of the heat conducting plate 130. Therefore, the jacket portion of the heat conducting plate 130 may be bent to accommodate the conduit 511. As previously discussed, the conduit 511 may allow coolant to flow to absorb heat from the second section 132 of the heat conducting plate 130. In other words, the conduit 511 may be in fluid flow communication with the cooling system 110 / heat pump 112 described above.

[0091] Reference Fig.15 , another embodiment of a heat conducting plate is shown at 230. The heat conducting plate 230 is used to define a portion of a housing for receiving a battery cell 20, which is provided in the form of a planar module. The heat conducting plate 230 includes a first section 231, a second section 232 and a third section 233, and substantially defines a U-shape. The first section 231 and the second section 232 are opposite to each other and are connected together via the third section 233. Figure 7 The same layered structure 100 described may be used for each of the sections 231 , 232 , 233 .

[0092] Heat can be transferred from the battery cell 20 to the first section 231 and the second section 232. The heat can then move to the third section 233, as described above with reference to Figure 8 The third section 233 may be in heat exchange relationship with another medium (eg, ambient air) to remove heat. The cooling system 110 including the conduit 111 as described above may be coupled to the third section 133 to extract heat therefrom.

[0093] Reference Fig.16 , another embodiment of the heat conducting plate is shown at 330. For the sake of simplicity, only the following description is made of Figure 6 The heat conductive plate 330 has different features. In the present embodiment, the heat conductive plate 330 has brackets 333 disposed on opposite edges 331A of the first section 331. Three brackets 333 are disposed on each side, but more or fewer brackets are contemplated. These brackets may allow the battery to be attached to the vehicle, as the heat conductive plate may also be used as a mechanical support for the unit and other components. The load path may extend from the frame member to the heat conductive plate via the bracket. Thus, the bracket may be configured to support the weight of the battery pack and any other forces applied to the battery pack, such as acceleration, vibration, shock, etc. Thus, the bracket may be load-bearing as defined above, and may not only be used for the purpose of maintaining the battery pack immobile.

[0094] Reference Fig.17 , another embodiment of the housing is shown at 116. The housing 116 includes six sides. Five of the six sides are defined by the heat conducting plate 430, and the sixth of the six sides is defined by the cover 117. The heat conducting plate 430 includes a battery cell 2 ( Figure 2 ) and four lateral sections 432 in heat exchange relationship with the bottom section 431. Each of the four lateral sections 432 extends substantially laterally from the edge of the bottom section 431. Figure 7 The same layered structure 100 described above can be used for the bottom section 431 and the side sections 432 of the heat conducting plate 430. The heat received from the battery cells 2 and transferred to the bottom section 431 can then be transferred to the environment outside the housing 116 via the four side sections 432. Fig. 9 A cooling system is described, which may be operatively coupled to the lateral section 432. Any number of walls of the housing may be condensers.

[0095] refer to Fig.18 In the embodiment shown, a bracket 35 is fixed to the first section 31 of the heat conducting plate 30. This bracket 35 can be used to fix the housing to an adjacent structure, such as the frame of an electric vehicle, via the heat conducting plate 30. The bracket 35 can be integrally manufactured as part of the heat conducting plate.

[0096] Reference now Figure 19-20, a bottom support 36 can be fixed to the first section 31 of the heat conductive plate 30 for supporting the battery cell 2, which is provided here as having a cylindrical shape. The bottom support 36 defines a plurality of cell engagement protrusions 37, each of which protrudes from the first section 31 of the heat conductive plate 30. Each cell engagement protrusion 37 can define a recess 37A, the size of which is suitable for receiving a corresponding one of the modules 2. These protrusions 37 can be made of a material with high thermal conductivity to transfer heat to the first section 31 of the heat conductive plate 30. The material can be, for example, aluminum. The cell engagement protrusion 37 can limit the movement of the module 2 in a plane parallel to the first section 31 of the heat conductive plate 30. This support 36 can facilitate the assembly of the battery cell 2 and improve the thermal contact with the heat conductive plate. The protrusion can extend perpendicular to the heat conductive plate to enhance the heat transfer normal to the heat conductive plate. This can reduce the temperature gradient along the battery cell.

[0097] References Figure 3 The heat conducting plate 10 described may include the Figure 6-18 For example, the heat conducting plate 10 may include one or more coolant pipes. A portion of the heat conducting plate 10 may wrap around the one or more coolant pipes.

[0098] Reference Fig.21 , an electric vehicle is shown at 600. The electric vehicle 600 includes wheels 601 driven by one or more electric motors 602, four wheels in the illustrated embodiment. In the illustrated embodiment, the electric motors 602 include a front electric motor driving a front wheel located at the front of the vehicle 600 and a rear electric motor driving a rear wheel located at the rear of the vehicle 600. Other configurations are contemplated. For example, each wheel 601 may be drivingly engaged by a corresponding electric motor. Thus, for a four-wheeled vehicle, four electric motors may be provided. Alternatively, a single electric motor may drive all wheels 601 via any suitable transmission.

[0099] The vehicle 600 has a chassis that generally includes a frame 604 for supporting the electric motor 602. In the illustrated embodiment, the chassis frame 604 includes longitudinal frame members 605 extending longitudinally between the front and rear of the vehicle 600, and includes transverse frame members 606 extending transversely between the right and left sides of the vehicle 600. The frame 604 is depicted here as being generally rectangular, but any other suitable shape may be used. The frame 604 may include trusses or any other support members to provide the frame 604 with the required rigidity while allowing the frame 604 to bear against the different components of the vehicle 600. The vehicle 600 includes a battery pack, which may correspond to any of the battery packs described above.

[0100] like Fig.21As shown in , the battery pack is load-bearing as defined herein. Therefore, the stiffness of the frame 604 can be increased by the battery pack, and the heat conductive plate 10 of the battery pack provides a load transfer path, through which the load is transferred between other structural components of the vehicle (or the structure with the battery pack installed inside). In other words, the heat conductive plate 10 of the battery pack can withstand and transfer loads during normal operation of the vehicle without buckling or failure. In the embodiment shown, the heat conductive plate of the battery pack may be responsible for increasing the stiffness of the frame 604. In this context, "increasing stiffness" means that a non-negligible part of the stiffness of the frame 604 is provided by the heat conductive plate. Such a non-negligible part can be, for example, at least 10% or more of the stiffness (for example, at least 20% or at least 30% of the stiffness). In other words, in some embodiments, the heat conductive plate can increase the stiffness of the frame 604 by at least 10%, at least 20%, and at least 30%. "Stiffness" is understood to include the resistance of the frame 604 to one or more of bending forces, shear forces, torsional forces, etc.

[0101] In the illustrated embodiment, one of the longitudinal frame members 605 is fixed to another of the longitudinal frame members 605 via the battery pack and its housing 1, 16, 116 containing the heat conductive plate. Therefore, the load path can be transmitted between the longitudinal frame members 605 through the heat conductive plate. The heat conductive plate of the battery pack and the housing can transfer the load between the transverse frame members 606 alternatively or in combination. Therefore, the heat conductive plate can be used as a web to resist one or more of the shear force, bending force, torsion force, etc. applied to the frame 604 of the vehicle 600 during normal use. The battery pack can define the bottom panel of the frame 604, so that the frame 604 can have no separate different panels. Therefore, the battery pack can be directly fixed (e.g., welded, fastened, etc.) to the frame 604 without the need for intermediate components. In other words, a typical battery pack can be fastened to a panel, which itself is fixed to the frame 604. In the present configuration, the electric vehicle 600 has no such panels, so that the battery pack and the housing (more specifically, the thermally conductive plate) act as support panels for supporting the cells 2 of the battery pack and for transferring and maintaining the loads applied to the frame 604 during use. In addition, the bottom wall or casing of the battery pack may face downward to the ground and be directly exposed to the environment outside the electric vehicle 600. The thermally conductive plate of the battery pack may define a face that is directly exposed to the environment. Therefore, the battery pack and the housing may have the required rigidity and resistance to protect the cells 2 without requiring another structural component of the frame 604. In some embodiments, the thermally conductive plate of the battery pack is responsible for providing the rigidity required to transfer loads between frame members and protect the cells 2.

[0102] The heat conducting plate can also withstand the loads applied to it by the weight of the unit 2, and can also withstand harsh operating conditions. For example, the heat conducting plate can withstand one or more of corrosion, erosion, vibration, acceleration, impact from foreign objects (e.g., gravel, stones, etc.). The heat conducting plate can be made of any suitable material, such as aluminum, stainless steel, etc., and can have a thickness or any suitable reinforcement (e.g., ribs) to withstand those loads and conditions. The heat conducting plate can comply with UL2271, UL2580, UL1642, UN38.3, ISO12405, IEC 62133, IEC 62660, SAE J2929, SAE J2464, and UL94-V0 standards.

[0103] Such a configuration may allow for a reduction in weight of the electric vehicle 600, as structural frame members may be omitted since their function is now assumed by the thermally conductive plates. Assembly of the electric vehicle 600 may be facilitated by this omission of some structural frame members. Additionally, heat transfer from and to the battery cells 2 via the thermally conductive plates may be increased by direct exposure to the environment, as there is no thermal resistance provided by the structural panels of the frame 604, as such panels may be omitted.

[0104] In the context of the present disclosure, the expression "substantially" is intended to encompass the differences imparted by manufacturing tolerances. The expression "about" means a variation of plus or minus 10%.

[0105] The embodiments described in this document provide non-limiting examples of possible implementations of the disclosed technology. After reviewing this disclosure, those of ordinary skill in the art will recognize that changes can be made to the embodiments described herein without departing from the scope of the disclosed technology. Those of ordinary skill in the art may implement additional modifications in view of the present disclosure, which modifications will be within the scope of the disclosed technology.

Claims

1. A battery pack comprising: a housing comprising interconnected walls; one or more battery cells housed in the housing; as well as A heat conducting plate defines one or more of the interconnecting walls and is structurally load bearing, the heat conducting plate having a first section, the one or more battery cells being in heat exchange relationship with the first section, and A second section is in heat exchange relationship with the first section, and the second section is in heat exchange relationship with an environment outside the housing to provide heat exchange between the one or more battery cells and the environment. 2 . The battery pack of claim 1 , wherein the one or more battery cells are secured to the first section of the thermally conductive plate. 3 . The battery pack of claim 1 , wherein the first segment and the second segment extend transversely to each other and each define a respective side of the housing.

4. The battery pack of claim 1 , wherein the first section comprises a first plate and the second section comprises a second plate, the thermally conductive plate comprises heat pipes mounted to both the first plate and the second plate, a heat pipe in the heat pipes extending from a first end on the first plate to a second end on the second plate. 5 . The battery pack of claim 4 , wherein the second plate has an inner side facing the one or more battery cells and an outer side opposite the inner side, the outer side defining fins. 6 . The battery pack of claim 4 , wherein the first plate and the second plate define a groove, the heat pipe being received within the groove. 7 . The battery pack according to claim 6 , wherein the first plate and the second plate are made of a material having a thermal conductivity of at least 10 W / mK.

8. The battery pack according to claim 1, wherein the thermally conductive plate comprises: a first shell and a second shell defining a cavity therebetween; A core assembly having a wicking layer adjacent to the inner side of the first shell, and a steam core, the wicking layer and the steam core being received within the cavity; and A working fluid is located in the cavity.

9. The battery pack of claim 8, comprising one or more coolant conduits embedded in the second section, the coolant conduits providing for the flow of coolant and being in fluid communication with a cooling system for extracting heat from the coolant.

10. The battery pack according to claim 8, comprising one or more coolant pipes, wherein the second section encloses the one or more coolant pipes, the coolant pipes providing a coolant flow and being in fluid communication with a cooling system for extracting heat from the coolant.

11. The battery pack of claim 8, comprising fins protruding from the second section of the thermally conductive plate.

12. The battery pack according to claim 8 comprises a third section, wherein the first section and the third section are connected together via the second section, the first section, the second section and the third section define a U-shape, and the one or more battery cells are located between the first section and the third section.

13. The battery pack of claim 8, wherein the first section includes four lateral sections each extending generally laterally from a respective edge of the second section, the four lateral sections and the second section defining the housing.

14. The battery pack of claim 1, comprising a battery support secured to the first section, the battery support defining a plurality of cell engagement tabs, each cell engagement tab defining a cavity that receives a respective one of the one or more battery cells.

15. An electric vehicle comprising: a chassis including a frame having frame members; as well as a battery pack fixed to the frame, the battery pack having: a housing comprising interconnected walls; one or more battery cells housed in the housing; as well as a heat conducting plate defining one or more of the interconnecting walls and being structurally load-bearing and configured to increase the rigidity of the frame, the heat conducting plate having a first section, the one or more battery cells being in heat exchange relationship with the first section, and A second section is in heat exchange relationship with the first section, and the second section is in heat exchange relationship with an environment outside the housing to provide heat exchange between the one or more battery cells and the environment. 16 . The electric vehicle according to claim 15 , wherein one of the frame members is fixed to the other of the frame members via the heat conduction plate.

17. The electric vehicle of claim 15, wherein the thermally conductive plate has a bottom surface exposed to an environment external to the electric vehicle.

18. The electric vehicle of claim 15, wherein the rigidity of the frame is increased by at least 10% by the heat conductive plate.

19. The electric vehicle of claim 15, comprising a bracket via which the thermally conductive plate is secured to the frame member, a load path extending from the frame member to the thermally conductive plate via the bracket, the bracket being configured to support the weight of a battery pack.

20. The electric vehicle of claim 15, wherein the thermally conductive plate is configured to support the weight of the one or more battery cells.

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