Multifunctional beam for electric vehicle battery pack

Abstract

The present disclosure describes a multi-functional integrated superbeam assembly structure having: an integrated structure, cooling and lateral elastic compliance functions; and thermal management propagation (TMP) protection. The superbeam assembly includes a pair of parallel panels, a coolant channel cover plate, and a coolant channel defined by the panels and one or more coolant channel cover plates. The structural design of the cooling channels and respective air gaps formed therebetween allow for the lateral elastic compliance of the super beam assembly to be adjusted to different amounts of elasticity. Top, bottom, and / or end structure channels may be included. A pair of TMP suppression channels may be attached to the superbeam assembly structure with an adhesive "thermal fuse" that preferentially melts and separates the pair of TMP suppression channels from the superbeam assembly during overheating in a TMP event.

Description

Technical Field

[0001] The present disclosure relates to structural support beams and thermal cooling plates for rechargeable battery packs in electric vehicles. More specifically, aspects of the present disclosure relate to multifunctional integrated structural support beams with internal cooling channels and adjustable lateral elastic compliance, and also include protection against thermal management propagation (TMP) events. Background Art

[0002] In rechargeable energy storage system (RESS) design, independent, separate components are used to achieve different functions within the battery pack. For example, some thick and rigid cross beams are used for structural integrity. Separate cooling plates are used to maintain battery cell temperature. Finally, aerogel or other elastic (compliant) materials are used to promote lateral pre-compression and accommodate lateral expansion of the battery cells during charging and recharging cycles. These separate components take up valuable space in the battery pack, resulting in a reduction in the overall battery pack energy density. Thermal management propagation (TMP) refers to a situation where the temperature of one battery cell rises rapidly and causes the temperature of adjacent battery cells to rise rapidly as well. Summary of the invention

[0003] As contemplated herein, a “super beam” assembly provides an integrated solution that combines a structural support beam with internal cooling channels and tunable lateral elastic compliance in a single, integrated multifunctional structure, including protection against TMP events.

[0004] In one or more embodiments, the super beam assembly includes a pair of parallel face plates, one or more coolant channel cover plates, and one or more coolant channels defined by the face plates and the one or more coolant channel cover plates. The structural design of the cooling channels and the corresponding air gaps formed therebetween allow the lateral elastic compliance of the super beam assembly to be adjusted to different elastic amounts. Optional top, bottom and / or end structural channels provide enhanced load bearing capacity.

[0005] In one example, a pair of TMP suppression channels may be attached to the super beam assembly structure using an adhesive "thermal fuse" that preferentially melts and causes the pair of TMP suppression channels to separate from the super beam assembly during overheating in a TMP event.

[0006] The multifunctional super beam assembly may further include: a left coolant inlet disposed at the proximal end of the left panel; a left coolant outlet disposed at the distal end of the left panel; a right coolant inlet disposed at the proximal end of the right panel; and a right coolant outlet disposed at the distal end of the right panel. The left coolant channel may have a C-shaped cross section, and the right coolant channel has a C-shaped cross section.

[0007] In an example, the multifunctional super beam assembly may have a left battery cell disposed adjacent to a left panel and a right battery cell disposed adjacent to a right panel. In another embodiment, a left thermal interface material (TIM) may be disposed between the left battery cell and the left panel; and a right TIM material may be disposed between the right battery cell and the right panel.

[0008] The super beam assembly may also include a top structural channel attached to the left panel and the right panel. The top structural channel may be attached to the left upper extension of the left panel; and may also be attached to the right upper extension of the right panel. The top structural channel may have a T-shaped or M-shaped cross section.

[0009] In an example, the multifunctional super beam assembly may further include: a left upper flange integrally attached to the left panel; and a right upper flange integrally attached to the right panel; wherein the top structural channel is attached to the left upper flange and the right upper flange. The top structural channel may be adhesively attached to the left upper flange with a left adhesive strip; and may be adhesively attached to the right upper flange with a right adhesive strip.

[0010] In another embodiment, the multifunctional super beam assembly may further include a bottom structural channel attached to the left panel; and the bottom structural channel is attached to the right panel. The bottom structural channel may have an I-shaped cross section. In another example, the left bottom of the left panel may have a sawtooth cross section; and the right bottom of the right panel may have a sawtooth cross section.

[0011] In an example, the multifunctional super beam assembly further includes: an upper air gap disposed between the left panel and the right panel; and a lower air gap disposed between the left panel and the right panel.

[0012] In one or more embodiments, the top structural channel and the bottom structural channel may have a width that is less than or equal to the width of the battery cell.

[0013] In an example, a super beam assembly further includes a top thermal management propagation (TMP) suppression channel attached to a top portion of the super beam assembly and a bottom TMP suppression channel attached to a bottom portion of the super beam assembly.

[0014] The super beam assembly may also include: an upper left flange integrally attached to the left panel; an upper right flange integrally attached to the right panel; a lower left flange integrally attached to the left panel; a lower right flange integrally attached to the right panel; an upper left thermal fuse disposed between the top TMP suppression channel and the upper left flange; an upper right thermal fuse disposed between the top TMP suppression channel and the upper right flange; a lower left thermal fuse disposed between the top TMP suppression channel and the lower left flange; and a lower right thermal fuse disposed between the top TMP suppression channel and the lower right flange.

[0015] In some embodiments, the top TMP suppression channel may include a plurality of upper Z-folded bellows segments; and the bottom TMP suppression channel includes a plurality of lower Z-folded bellows segments.

[0016] Finally, in one embodiment, an electric vehicle may include: an electric motor vehicle body; a battery pack connected to the electric motor vehicle body; and a plurality of integrated super beam assemblies disposed inside the battery pack; wherein each super beam assembly includes: a left panel; a right panel; one or more left coolant channel covers; one or more right coolant channel covers; one or more left coolant channels defined by the left panel and the one or more left coolant channel covers; and one or more right coolant channels defined by the right panel and the one or more right coolant channel covers; and wherein the left panel is oriented parallel to the right panel.

[0017] The present invention also includes the following scheme:

[0018] Solution 1. A multifunctional integrated beam assembly with integrated structural, cooling and lateral elastic compliance functions, comprising:

[0019] (a) Left panel;

[0020] (b) right panel;

[0021] (c) one or more left coolant channel covers;

[0022] (d) one or more right coolant channel covers;

[0023] (e) one or more left coolant passages defined by the left panel and one or more left coolant passage covers; and

[0024] (f) one or more right coolant passages defined by the right panel and the one or more right coolant passage cover plates;

[0025] wherein the one or more left coolant channel cover plates are attached to the left panel;

[0026] wherein the one or more right coolant channel covers are attached to the right panel; and

[0027] Wherein, the left panel is oriented parallel to the right panel.

[0028] Solution 2. The multifunctional integrated beam assembly according to Solution 1 further includes:

[0029] a left coolant inlet disposed at a proximal end of the left panel;

[0030] a left coolant outlet disposed at a distal end of the left panel;

[0031] a right coolant inlet disposed at a proximal end of the right panel; and

[0032] A right coolant outlet is disposed at a distal end of the right panel.

[0033] Solution 3. The multifunctional integrated beam assembly according to Solution 1,

[0034] wherein the one or more left coolant passages have a C-shaped cross-section; and

[0035] Wherein, the one or more right coolant channels have a C-shaped cross section.

[0036] Solution 4. The multifunctional integrated beam assembly according to Solution 1 further includes:

[0037] a left battery unit disposed adjacent to the left panel; and

[0038] A right battery unit is disposed adjacent to the right panel.

[0039] Solution 5. The multifunctional integrated beam assembly according to Solution 4 further includes:

[0040] a left thermal interface material (TIM) disposed between the left battery cell and the left panel; and

[0041] A right thermal interface material (TIM) is disposed between the right battery cell and the right panel.

[0042] Option 6. The multifunctional integrated beam assembly according to Option 1 further includes a top structural channel attached to the left panel and the right panel.

[0043] Option 7. A multifunctional integrated beam assembly according to Option 6, wherein the top structural channel is attached to the upper left extension of the left panel and to the upper right extension of the right panel.

[0044] Option 8. A multifunctional integrated beam assembly according to Option 6, wherein the top structural channel has a T-shaped or M-shaped cross-section.

[0045] Solution 9. The multifunctional integrated beam assembly according to Solution 6 further includes:

[0046] integrally attached to the left upper flange of the left panel; and

[0047] integrally attached to the right upper flange of the right panel;

[0048] Wherein, the top structural channel is attached to the left upper flange and the right upper flange.

[0049] Solution 10. The multifunctional integrated beam assembly according to Solution 9,

[0050] wherein the top structural channel is adhesively attached to the left upper flange using a left adhesive strip; and

[0051] Wherein, the top structural channel is adhesively attached to the right upper flange using a right adhesive strip.

[0052] Option 11. The multifunctional integrated beam assembly according to Option 1 further includes a bottom structural channel attached to the left panel and the right panel.

[0053] Option 12. A multifunctional integrated beam assembly according to Option 11, wherein the bottom structural channel has an I-shaped cross-section.

[0054] Solution 13. The multifunctional integrated beam assembly according to Solution 1,

[0055] wherein the left bottom portion of the left panel has a sawtooth-shaped cross section; and

[0056] Wherein, the right bottom of the right panel has a sawtooth cross-section.

[0057] Solution 14. The multifunctional integrated beam assembly according to Solution 1 further includes:

[0058] one or more upper air gaps disposed between the left panel and the right panel; and

[0059] One or more lower air gaps are disposed between the left panel and the right panel.

[0060] Option 15. A multifunctional integrated beam assembly according to Option 6, wherein the top structural channel has a width less than or equal to the width of the battery cell.

[0061] Option 16. A multifunctional integrated beam assembly according to Option 11, wherein the bottom structural channel has a width less than or equal to the width of the battery cell.

[0062] Solution 17. A multifunctional integrated beam assembly having integrated structural, cooling and lateral elastic compliance functions, comprising:

[0063] (a) Left panel;

[0064] (b) right panel;

[0065] (c) one or more left coolant channel covers;

[0066] (d) one or more right coolant channel covers;

[0067] (e) one or more left coolant passages defined by the left panel and the one or more left coolant passage covers;

[0068] (f) one or more right coolant passages defined by the right panel and the one or more right coolant passage cover plates;

[0069] (g) a top thermal management propagation (TMP) suppression channel attached to a top portion of the superbeam assembly; and

[0070] (h) a bottom TMP suppression channel attached to a bottom portion of the superbeam assembly; and

[0071] Wherein, the left panel is oriented parallel to the right panel.

[0072] Solution 18. The multifunctional integrated beam assembly according to Solution 17 further includes:

[0073] integrally attached to an upper left flange of the left panel;

[0074] integrally attached to the right upper flange of the right panel;

[0075] integrally attached to a left lower flange of the left panel;

[0076] integrally attached to a right lower flange of the right panel;

[0077] an upper left thermal fuse disposed between the top TMP suppression channel and the upper left flange;

[0078] an upper right thermal fuse disposed between the top TMP suppression channel and the upper right flange;

[0079] a lower left thermal fuse disposed between the bottom TMP suppression channel and the lower left flange; and

[0080] A right lower thermal fuse is disposed between the bottom TMP suppression channel and the right lower flange.

[0081] Solution 19. The multifunctional integrated beam assembly according to Solution 17,

[0082] wherein the top TMP suppression channel comprises one or more upper Z-folded bellows sections; and

[0083] Wherein, the bottom TMP suppression channel includes one or more lower Z-folded bellows sections.

[0084] Solution 20. An electric vehicle, comprising:

[0085] Electric motor vehicle bodies;

[0086] a battery pack connected to the electric motor vehicle body; and

[0087] One or more multifunctional integrated beam assemblies, which are arranged inside the battery pack, wherein each multifunctional integrated beam assembly includes:

[0088] (a) Left panel;

[0089] (b) right panel;

[0090] (c) one or more left coolant channel covers;

[0091] (d) one or more right coolant channel covers;

[0092] (e) one or more left coolant passages defined by the left panel and the one or more left coolant passage covers; and

[0093] (f) one or more right coolant passages defined by the right panel and the one or more right coolant passage covers; and

[0094] Wherein, the left panel is oriented parallel to the right panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0095] Figure 1 A schematic perspective view of an example of a battery pack for an electric vehicle having five large structural beams spanning the width of the battery pack is shown.

[0096] Figure 2 A schematic perspective view of an example of a battery pack for an electric vehicle having a plurality of multifunctional super beam assemblies between pairs of adjacent battery cells according to the present disclosure is shown.

[0097] Figure 3AA schematic perspective view of an example of a half-section of a superbeam assembly having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown.

[0098] Figure 3B A schematic cross-sectional elevational view (end view) of an example of a half-section of a superbeam assembly having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown (Section AA).

[0099] Figure 4 A schematic cross-sectional elevational view (end view) (section AA) of an example of a complete super beam assembly according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels is shown.

[0100] Figure 5 A schematic cross-sectional elevational view (end view) (Section DD) of an example of a complete super beam assembly according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels is shown.

[0101] Figure 6 A schematic cross-sectional elevational view (end view) of an example of a top structural channel according to the present disclosure is shown (Section AA).

[0102] Figure 7 A schematic perspective view of an example of a half 14 of a super beam assembly having integrated structural, cooling and lateral elastic compliance functions and four integrated flange sections according to the present disclosure is shown.

[0103] Figure 8 A schematic cross-sectional elevational view (end view) (section AA) of an example of a superbeam assembly according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions and two pairs of longitudinal integrated flanges respectively attached to each panel is shown.

[0104] Fig. 9 Shown is a schematic exploded perspective view of an example of two half sections of a super beam assembly according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions and an integrated perimeter flange and top structural channel.

[0105] Fig.10 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown (Section AA).

[0106] Fig.11A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown (Section AA).

[0107] Fig.12 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown (Section AA).

[0108] Fig.13 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown (Section AA).

[0109] Fig.14 A schematic perspective cross-sectional front view (side view) (Section CC) of an example of a super beam assembly according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions, as well as top and bottom structural channels and a pair of vertical frame skin beams is shown.

[0110] Fig.15 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels according to the present disclosure is shown (Section AA).

[0111] Fig.16 A schematic cross-sectional elevational view (end view) of an example of a top structural channel according to the present disclosure is shown (Section AA).

[0112] Fig.17 A schematic cross-sectional elevational view (end view) of an example of a super beam assembly panel having a pair of vertical extensions according to the present disclosure is shown (Section AA).

[0113] Fig.18 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly panel having integrated perimeter top and bottom flanges according to the present disclosure is shown (Section AA).

[0114] Fig.19 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly panel having integrated top and bottom perimeter flanges according to the present disclosure is shown (Section AA).

[0115] Fig. 20 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels according to the present disclosure is shown (Section AA).

[0116] Fig.21 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels according to the present disclosure is shown (Section AA).

[0117] Fig. 22 A schematic cross-sectional plan (top) view (Section BB) of an example of half of a superbeam assembly having integrated structural, cooling and lateral elastic compliance functions and an integrated perimeter flange according to the present disclosure is shown.

[0118] Fig.23 A schematic perspective view of an example of an electric vehicle with an integrated battery pack according to the present disclosure is shown.

[0119] Fig.24 A schematic perspective view of an example of a complete super beam assembly with full complement of adjacent battery cells according to the present disclosure is shown.

[0120] Fig.25A A schematic side view of an example of a pair of vertical end structural channels attached to the proximal and distal ends of a super beam assembly according to the present disclosure is shown.

[0121] Fig.25B A schematic plan (top) cross-sectional view (Section BB) of an example of a pair of vertical end structural channels attached to the proximal and distal ends of a superbeam assembly according to the present disclosure is shown.

[0122] Fig.26 A schematic cross-sectional view (section AA) of an example of four super beam assemblies having five adjacent battery cells according to the present disclosure is shown.

[0123] Fig. 27 A schematic perspective view of an example of seven Super Beam Assemblies holding thirty-two battery cells arranged in seven parallel rows in a battery pack assembly according to the present disclosure is shown.

[0124] Fig.28 A schematic cross-sectional view (section AA) of an example of a superbeam assembly holding two battery cells according to the present disclosure is shown, with top and bottom TMP suppression channels.

[0125] Fig.29A A schematic cross-sectional view (section AA) of an example of a top TMP suppression channel according to the present disclosure is shown.

[0126] Fig.29B A schematic cross-sectional view (section AA) of an example of a top TMP suppression channel having a pair of four Z-folded bellows sections according to the present disclosure is shown.

[0127] Fig.30 A schematic perspective cross-sectional view (section AA) of an example of a top TMP-suppressing channel having a series of slots according to the present disclosure is shown.

[0128] Fig.31 A schematic perspective cross-sectional view (section AA) of an example of a top TMP-suppressing channel having a series of multiple perforations according to the present disclosure is shown.

[0129] Fig.32 A schematic perspective cross-sectional view (section AA) of an example of a top TMP suppressing channel having a central groove according to the present disclosure is shown.

[0130] Fig.33 A schematic perspective view of a battery pack frame housing having a single super beam assembly oriented longitudinally (side to side) in the X-direction according to the present disclosure is shown.

[0131] Fig.34 A schematic perspective view of a battery pack frame housing having a single super beam assembly oriented longitudinally (front to back) in the Y direction according to the present disclosure is shown. DETAILED DESCRIPTION

[0132] The present disclosure includes examples in many different forms. Representative examples of the present disclosure are shown in the accompanying drawings and will be described in detail herein, and it should be understood that these examples are provided as examples of the disclosed principles, rather than limitations on the broad aspects of the present disclosure. In this regard, elements and limitations such as those described in the abstract, background technology, summary of the invention, and detailed description but not explicitly set forth in the claims should not be incorporated into the claims individually or collectively by implication, inference, or otherwise.

[0133] For the purposes of this detailed description, unless specifically disclaimed: the singular encompasses the plural, and vice versa; the words "and" and "or" shall be both conjunctive and disjunctive; the words "any" and "all" shall mean "any and all"; and the words "include," "comprising," "containing," "having," and the like shall each mean "including but not limited to." In addition, approximate words, such as "approximately," "almost," "substantially," "generally," "approximately / roughly," and the like, may each be used herein in the sense of, for example, "at, close to, or nearly at," or "within 0-5% of ...," or "within an acceptable manufacturing tolerance," or any logical combination thereof.

[0134] Unless otherwise specified from the context, as used herein, the term "about" should be understood to be within the normal tolerance range in the art, such as within 2 standard deviations of the mean. "About" can be understood to be within 10%, 5%, 1%, 0.5%, 0.1%, 0.05% or 0.01% of the stated value. "About" can alternatively be understood to imply the exact value stated. Unless clearly apparent from the context, the numerical values ​​provided herein are modified by the term "about".

[0135] Finally, directional adjectives and adverbs, such as front, rear, inside, outside, starboard, port, vertical, horizontal, upward, downward, forward, backward, left, right, etc., may be used with respect to a motor vehicle, such as the forward driving direction of a motor vehicle when the vehicle is operatively oriented on a level driving surface. The directions "left" and "right" are represented by Figure 4 , Figure 5 , Figure 8 , Figure 10-13 , Fig.15 , Figure 20-21 and Fig.28 The view shown in section AA is defined. For example, in Figure 4 , the "left" panel is item #18, and the "right" panel is item #18'.

[0136] In some examples, when referring to "lateral elastic compliance", the word "lateral" refers to the lateral direction with respect to, for example, Figure 2 , 18'). The word "lateral" also refers to a direction perpendicular to the parallel planes of panels 18 and 18'. The phrases "structural channels", "structural caps" and "structural beams" are used interchangeably. The phrase "super beam assembly" refers to an integrated beam structure including a pair of panels and a pair of attached cover plates, the pair of attached cover plates defining a pair of corresponding cooling channels that cool each panel. The phrase "structural channels" includes "structural beams"; and they can have complex cross-sectional shapes, including but not limited to: I-beams, L-beams, T-beams, M-beams and zigzag beams.

[0137] Figure 1 A schematic perspective view of an example of a battery pack frame housing 8 for an electric vehicle is shown, the battery pack frame housing having five large structural cross beams 12, 12', etc., which span the entire width of the battery pack frame housing 8 in the X direction. Also shown are two frame housing structural side beams 20 and 20', which extend along the length of the battery pack frame housing 8 in the Y direction, which protect the batteries from lateral forces F.

[0138] Figure 2A schematic perspective view of an example of a battery pack frame housing 8 for holding a battery pack 10 for an electric vehicle according to the present disclosure is shown, wherein a plurality of super beam assemblies 16, 16', etc. are located between pairs of adjacent battery cells 26, 26' and are oriented perpendicular to the frame housing beams 20 and 20' for protection from lateral forces F. The frame housing 8 also includes a pair of structural beams 6 and 6' oriented in the X direction.

[0139] Figure 3A A schematic perspective view of an example of a cross-section of a half 14 of a super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions according to the present disclosure is shown. The half 14 of the super beam assembly 16 includes a left panel 18 extending longitudinally in the X direction, which has an attached C-shaped left coolant channel cover plate 28, which has a shape defining an internal coolant channel (see Figure 4 ) of the perimeter 130. The coolant inlet 22 and the coolant outlet 24 cannot be seen in this view. In this example, no perimeter flange is attached to the panel 18.

[0140] Figure 3B A schematic cross-sectional elevational view (end view) of an example of a half-section 14 of a super beam assembly 16 having integrated structural, cooling, and lateral elastic compliance functions according to the present disclosure is shown (section AA). The half-section 14 of the super beam assembly 16 includes a vertical panel 18, wherein the battery cells are disposed adjacent to the panel 18. A C-shaped coolant channel cover 28 is attached to the panel 18 around a perimeter 130 of the cover 28. The coolant channel 30 is defined by the panel 18 on one side of the coolant channel 30 and the C-shaped coolant channel cover 28 on the other side of the coolant channel 30. The coolant channel 30 is hermetically sealed by the perimeter joint 130. The perimeter joint 130 may include a welded, brazed, or adhesively attached connection.

[0141] Figure 4A schematic cross-sectional elevational view (end view) of an example of a complete super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions and having top and bottom structural channels 32 and 38, respectively, according to the present disclosure is shown (section AA). The super beam assembly 16 includes two halves, namely, a first half section 14 and a second half section 14' (which is a mirror image of the first half section 14). The super beam assembly 16 includes a pair of vertical, spaced apart, parallel left and right panels 18 and 18', which extend longitudinally in the X direction, respectively. A pair of left and right battery cells 26 and 26' are positioned adjacent to the left and right panels 18 and 18', respectively. Attached left and right C-shaped coolant channel covers 28 and 28' are attached to the left and right panels 18 and 18', respectively. The left and right coolant channel covers 28 and 28' define a pair of left and right C-shaped internal coolant channels 30 and 30', respectively. A pair of upper and lower air gaps 29 and 29' are located between the left and right panels 18 and 18', respectively, and are located outside the left and right inner coolant passages 30 and 30', respectively. The presence of the air gaps 29 and 29' between the adjacent left and right panels 18 and 18' increases the lateral elastic compliance of the super beam assembly 16 in the lateral direction (i.e., the Y direction).

[0142] Still refer to Figure 4 , the top structural channel 32 may include a T-shaped upper structural channel 34 having a hollow section 44 of a web 47 and a pair of integrated left and right upper flanges 36 and 36'. The left upper flange 36 and the right upper flange 36' are integrally attached to the left panel 18 and the right panel 18', respectively. The T-shaped upper structural channel 34 can be attached to the left upper flange 36 and the right upper flange 36', for example, by welding or brazing joints. Alternatively, left and right adhesive strips 76 and 76' can be used to adhesively attach the T-shaped upper structural channel 34 to the left and right upper flanges 36 and 36', respectively. The T-shaped upper structural channel 34 can be made of, for example, extruded steel or extruded aluminum alloy. In one example, the hollow section 44 of the web 47 can be filled with a solid material, which can be the same or different from the material used to manufacture the top structural channel 32.

[0143] Still refer to Figure 4, the bottom structural channel 38 includes a T-shaped lower structural channel 40 having a hollow section 39 of a web 49, and a pair of left lower flanges 42 and right lower flanges 42', respectively, which are integrated. The left lower flange 42 and the right lower flange 42' are respectively attached to the bottom of the left panel 18 and the right panel 18'. The T-shaped lower structural channel 40 can be attached to the lower flanges 42 and 42', for example, by welding or brazing joints. Alternatively, left and right adhesive strips 76 and 76' can be used to adhesively connect the T-shaped lower structural channel 40 to the left and right lower integrated flanges 42 and 42', respectively. The T-shaped lower structural channel 40 can be made of, for example, extruded steel or extruded aluminum alloy. In one example, the hollow section 39 of the web 49 can be filled with a solid material, which can be the same or different from the material used to manufacture the bottom structural channel 38.

[0144] Figure 5 A schematic cross-sectional front view (end view) (section DD) of an example of a complete super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels 32 and 38, respectively, according to the present disclosure is shown. The super beam assembly 16 includes a pair of spaced-apart parallel left and right panels 18 and 18', which extend longitudinally in the X direction. The left battery cell 26 and the right battery cell 26' are not shown in this view. C-shaped left and right coolant channel covers 28 and 28' are attached to the left and right panels 18 and 18', respectively. The left and right coolant channel covers 28 and 28' define a pair of left and right C-shaped internal coolant channels 30 and 30', respectively. In this cross-sectional view, the left and right coolant inlets 22 and 22' supply coolant 70 and 70' to the left and right coolant channels 30 and 30', respectively.

[0145] Figure 6 A schematic cross-sectional front view (section AA) of an example of a top structural channel 32 according to the present disclosure is shown. The top channel 32 has an integral T-shaped cross-section, which includes a pair of left and right horizontal flanges 46 and 46', respectively, with a pair of integrated vertical web sections 41 and 41'. A hollow space 44 is provided between the pair of web sections 41 and 41'. The T-shaped top structural channel 32 can be made of, for example, extruded steel or extruded aluminum alloy. In one example, the hollow section 44 can be filled with a solid material, which can be the same or different from the material used to manufacture the top structural channel 32.

[0146] Figure 7A schematic perspective view of an example of a half 14 of a super beam assembly 16 according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions and four examples of integrated flange segments 90, 48, 92 and 54 is shown. The half 14 of the super beam assembly 16 includes an elongated panel 18 extending longitudinally in the X direction. An attached shaped coolant channel cover plate 28 having a perimeter 130 defines an internal coolant channel (not shown in this view). See FIG. Figure 4 The proximal and distal coolant inlets 22 and outlets 24 are located at opposite ends of the panel 18 , but are not visible in this view. Four integral flange sections 90 , 48 , 92 , and 54 are integrally attached to the panel 18 .

[0147] Figure 8 A schematic cross-sectional elevational view (end view) (section AA) of an example of a super beam assembly 16 according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions and two pairs of left and right longitudinal integrated flange sections (48, 54) and (48', 54') attached to the left and right panels 18', 18', respectively. The left and right integrated flange sections (48, 54) and (48', 54') are configured to hold battery cells 26 and 26', respectively. Figure 8 The remaining characteristics of Figure 4 The remaining features are the same and will not be repeated here.

[0148] Fig. 9 A schematic exploded perspective view of an example of two half beam sections 14 and 14' of a single super beam assembly 16 according to the present disclosure having integrated structural, cooling and lateral elastic compliance functions, integrated perimeter flanges (48, 54) and (48', 54') and a top structural channel 32 is shown. The integrated perimeter flanges include four integrated perimeter flange sections 90, 48, 92 and 54 for the left half section 14 of the super beam assembly 16 and flange sections 90', 48', 92' and 54' for the right half section 14' of the super beam assembly 16. The left half section 14 of the super beam assembly 16 includes a face plate 18 extending longitudinally in the X direction having an attached C-shaped coolant channel cover plate 28 having a C-shaped internal coolant channel (see FIG. 1 ) defining a C-shaped internal coolant channel. Figure 4 ) perimeter 130, 130'. The proximal and distal coolant inlets 22, 22' and outlets 24, 24' in the panels 18 and 18' and their corresponding proximal and distal holes 50, 52 and 50', 52' are located at opposite ends (i.e., distal and proximal ends) of the panels 18, 18', respectively, and they supply the flowing coolant 70 to the internal cooling channels 30, 30' defined by the coolant channel covers 28 and 28' (see Figure 4 ).

[0149] Next, Fig.10 , Fig.11 , Fig.12 and Fig.13 A different cooling channel design is shown using the same pair of left and right panels 18 , 18 ′.

[0150] Fig.10 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly 16 having integrated structural, cooling, and lateral elastic compliance functionality according to the present disclosure is shown (Section AA). Fig.10 and Figure 4 The same, except that a pair of left and right battery cells 26 and 26' have been removed for clarity, and lateral force arrows 108 and 108' have been added. The super beam assembly 16 includes a pair of parallel panels 18 and 18' separated by a gap 200. The width of the gap 200 can change (e.g., decrease) as the battery cells expand during the charging and recharging cycles. C-shaped coolant channel covers 28 and 28' are attached to the left panel 18 and the right panel 18', respectively. The left coolant channel cover plate 28 and the right coolant channel cover plate 28' define a pair of large-sized C-shaped opposing left internal coolant channels 30 and right internal coolant channels 30', respectively. A pair of upper air gaps 29 and lower air gaps 29' are located between the left panel 18 and the right panel 18', respectively, and are located on the outside of the left internal coolant channel 30 and the right internal coolant channel 30', respectively. For clarity, the optional top and bottom structural channels 32 and 38 have been removed.

[0151] Still reference Fig.10 , a set of inwardly facing lateral force arrows 108 and 108' are shown, which point along the Y direction. These lateral compressive forces (i.e., lateral pressures) can be generated by two different sources: (1) pre-compression of the battery pack 10 using pre-loaded bolts (not shown) that extend through the frame housing 8 in the Y direction, and (2) progressive lateral expansion of the battery cells in the Y direction caused by repeated charge / discharge cycles while being limited by rigid constraints. The relatively thin left and right C-shaped cover plates 28, 28' are inherently elastically compliant in the lateral direction (i.e., because the thin cover plates 28 and 28' elastically flex like springs when loaded by the lateral inwardly facing forces 108 and 108', respectively).

[0152] Fig.11A schematic cross-sectional elevational view (end view) of an example of a super beam assembly 16 with integrated structural, cooling and lateral elastic compliance functions according to the present disclosure is shown (section AA). Ten relatively medium-sized left and right coolant channels 30, 30', etc. are shown. The relatively thin left and right cover plates 28, 28' are inherently elastically compliant in the lateral direction (i.e., the Y direction) because they elastically flex like springs when loaded by lateral compressive forces 108 and 108', respectively. For clarity, the optional top and bottom structural channels 32 and 38 have been removed.

[0153] Fig.12 A schematic cross-sectional elevational view (end view) (section AA) of an example of a super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions according to the present disclosure is shown. Nine medium-sized alternating left and right coolant channels 30, 30', etc. are shown. The relatively thin left cover plate 28 and the right cover plate 28' are inherently elastically compliant in the lateral direction (i.e., the Y direction) because they elastically flex like springs when loaded by lateral compressive forces 108 and 108', respectively. A pair of upper air gaps 29 and lower air gaps 29' are located between the left panel 18 and the right panel 18', respectively, and are located on the outside of the left internal coolant channel 30 and the right internal coolant channel 30', respectively. For clarity, the optional top and bottom structural channels 32 and 38 have been removed.

[0154] Fig.13 A schematic cross-sectional elevational view (end view) (section AA) of an example of a super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions according to the present disclosure is shown. Twenty relatively small-sized left and right coolant channels 30, 30', etc. are shown. The relatively thin, small left C-shaped cover plate 28 and right C-shaped cover plate 28' are inherently elastically compliant in the lateral direction (i.e., the Y direction) because they elastically flex like springs when loaded by lateral compressive forces 108 and 108', respectively. A pair of upper air gaps 29 and lower air gaps 29' are located between panels 18 and 18', respectively, and are located outside the left inner coolant channel 30 and the right inner coolant channel 30', respectively. For clarity, the optional top and bottom structural channels 32 and 38 have been removed.

[0155] Above about Fig.10 , Fig.11 , Fig.12 and Fig.13 The examples discussed show four different coolant channel configurations that allow the lateral elastic compliance to be tuned or adjusted to a specific desired amount of elastic compliance, depending on the requirements of the battery pack design.

[0156] Fig.14A schematic perspective cross-sectional (Section CC) side view of a single example of a super beam assembly 16 according to the present disclosure is shown, having integrated structural, cooling and lateral elastic compliance functions, top and bottom structural channels 32 and 38, and a pair of left and right horizontal frame shell structural beams 20 and 20' aligned in the X direction. The top and bottom structural channels 32 and 38 and the panel 18 and coolant channel cover 28 span the entire distance from one frame shell beam 20 to the opposite frame shell beam 20'. The coolant 70 flows horizontally in the Y direction. The left and right frame shell side beams 20 and 20' are oriented perpendicular to the top and bottom structural channels 32 and 38, respectively, and protect the battery cells when subjected to lateral forces F in the Y direction (see Figure 4 ) and coolant channels (see Figure 4 ).

[0157] Fig.15 A schematic cross-sectional elevational view (end view) of an example of a super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions and top and bottom structural channels 72 and 74, respectively, according to the present disclosure is shown (Section AA). For clarity, the left battery cell 26 and the right battery cell 26' are not shown. The bottom structural channel 74 includes a pair of L-shaped channels 42 and 42'. Next, in Fig.16 Details of the top structural channel 72 are shown in the discussion of FIG.

[0158] Fig.16 A schematic cross-sectional orthotropic front view (end view) (section AA) of an example of a top structural channel 72 according to the present disclosure is shown. The top structural channel 72 has an M-shaped cross-section and includes a horizontal top plate 80 having a pair of integrated left and right vertical side walls 86 and 86', which straddle left and right vertical extensions 97 and 97' of left and right panels 18 and 18', respectively. The top structural channel also includes an integrated V-shaped center web section 88. The center section 44 of the V-shaped center web section 88 can be hollow. In some examples, the left and right integrated side walls 86 and 86' can be adhesively attached to the left and right upper vertical extensions 97 and 97' of the left and right panels 18 and 18', respectively, with left and right vertical adhesive strips 152 and 152'. In one example, the hollow section 72 can be filled with a solid material, which can be the same or different from the material used to manufacture the top structural channel 72.

[0159] Fig.17A schematic cross-sectional elevational view (end view) of an example of a super beam assembly panel 18 having a pair of integrated vertical extensions 97 and 97' according to the present disclosure is shown (Section AA). The panel 18 extends vertically beyond the top and bottom ends of the battery cells 26 with integrated, straight, vertical top and bottom extensions 97 and 98, respectively. For clarity, coolant channels are not shown.

[0160] Fig.18 A schematic cross-sectional elevational view (end view) of an example of a super beam assembly panel 18 having integrated L-shaped top and bottom perimeter flanges 48 and 54, respectively, and a battery cell 26 adjacent to the panel 18 is shown (section AA). The addition of the integrated top and bottom perimeter flanges 48 and 54 increases the bending stiffness (and load bearing capacity) of the super beam assembly 16. Both flange portions 48 and 54 of the panel 18 face inwardly, toward the battery cell 26 (i.e., in the negative Y direction). For clarity, coolant channels are not shown. The width of the flanges 48 and 54 can be less than or equal to half the width of the battery cell 26 (to allow for a compact assembly of multiple super beam assemblies placed side by side).

[0161] Fig.19 A schematic cross-sectional elevational view (end view) of an example of a super beam assembly panel 18 with integrated L-shaped top and bottom perimeter flanges 48 and 110 according to the present disclosure is shown (Section AA). The upper flange 48 faces inward (i.e., to the left), and the lower flange 110 faces outward (i.e., to the right). For clarity, coolant channels are not shown. The width of the flanges 48 and 110 can be less than or equal to half the width of the battery cell 26 (to allow for a compact assembly of multiple super beam assemblies placed side by side).

[0162] Fig. 20 A schematic cross-sectional elevational view (end view) of an example of a superbeam assembly 16 having integrated structural, cooling, and lateral elastic compliance functionality and top and bottom structural channels 72 and 118, respectively, according to the present disclosure is shown (Section AA). Fig.16 The top structural channel 72 is shown in more detail in FIG. Fig.16 As shown, the left upper extension 97 and the right upper extension 97' of the left panel 18 and the right panel 18' are respectively inserted into the top structural channel 72. The lower ends of the left panel 18 and the right panel 18' include a left flange section 116 and a right flange section 116' facing outward, respectively. For clarity, pairs of adjacent battery cells are not shown. The bottom structural channel 118 can have an I-shaped cross-section.

[0163] Fig.21A schematic cross-sectional elevational view (end view) of an example of a super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions and a top structural channel 122 and bottom structural channels 78 and 78' according to the present disclosure is shown (Section AA). The top structural channel 122 may include an inverted U-shaped cross-sectional shape 120 that straddles the left and right upper extensions 97 and 97' of the left and right panels 18 and 18', respectively. The inverted U-shaped structural channel 120 may be adhesively attached to the left and right upper extensions 97 and 97' of the left and right panels 18 and 18', respectively. The bottom left end 78 and the bottom right end 78' of the left and right panels 18 and 18', respectively, include a left integrated flange 78 and a right integrated flange 78' having a "dog leg" or sawtooth cross-sectional shape.

[0164] Fig. 22 A schematic cross-sectional plan view (section BB) of an example of a super beam assembly 16 having integrated structural, cooling and lateral elastic compliance functions and integrated perimeter flanges 90 and 92 according to the present disclosure is shown. The battery cells 26, 26', 26", and 26'" are located between the integrated perimeter flanges 90 and 92 and are disposed adjacent to the panel 18. An optional compliant thermal interface material (TIM) layer 106 may be disposed between the battery cells 26 and the panel 18. The TIM layer 106 may be an adhesive and may be used to bond the battery cells 26 to the panel 18. The coolant channel 30 is defined by the panel 18 on one side and the cover plate 28 on the other side. The coolant 70 flows into the inlet port 22, then flows horizontally through the coolant channel 30 in the X direction, and finally flows out through the outlet port 24.

[0165] Fig.23 A schematic perspective view of an example of an electric motor vehicle 94 having a rechargeable battery pack 10 according to the present disclosure is shown. The electric motor vehicle 94 includes a vehicle body 96, a passenger compartment 98, a plurality of wheels 100, 100', etc. attached to the vehicle body 96, and a rechargeable battery pack 10 located inside the electric motor vehicle 94. The electric motor vehicle 94 also includes a traction electric motor 104 attached to the vehicle body 96, which is operable to drive one or more wheels 100, 100', etc., which propel the electric motor vehicle 94. The rechargeable battery pack 10 is attached to the vehicle body 96 and is electrically connected to the traction motor 104 via a power cable 102.

[0166] Fig.24A schematic perspective view of an example of a super beam assembly 132 with fully complementary left and right battery cells 26, 26', etc., according to the present disclosure is shown. The assembly 132 includes a pair of left and right panels 18, 18' with left and right coolant inlets 22, 22', and four pairs of left and right battery cells 26, 26', etc., located on both sides of the left and right panels 18, 18', respectively, and arranged along the length of the assembly 132 in the X direction. The internal cooling channels cannot be seen in this illustration. The bottom left and right structural channels 78 and 78' are shown.

[0167] Fig.25A A schematic side view of an example of a pair of vertical end structural channels 190 and 192 attached to a proximal end 194 and a distal end 196, respectively, of a super beam assembly 16 according to the present disclosure is shown. In this example, the super beam assembly 16 includes a right panel 18.

[0168] Fig.25B A schematic plan (top) cross-sectional view (section BB) of an example of a pair of vertical end structural channels 190 and 192 attached to the proximal end 194 and distal end 196 of the super beam assembly 16, respectively, according to the present disclosure is shown. The super beam assembly 16 includes right and left panels 18, 18'; and also includes left and right coolant channel cover plates 28' and 28. The super beam assembly 16 also includes left and right coolant channels 30' and 30. The end structural channels 190 and 192 can hermetically seal the proximal ends 194 and distal ends 196 of the left and right coolant channels 30 and 30', respectively.

[0169] Fig.26 A schematic cross-sectional view (section AA) of an example of four adjacent super beam assemblies supporting five battery cells 26A, 26B, 26C, 26D, and 26E according to the present disclosure is shown. The super beam assemblies 16A, 16B, 16C, and 16D are oriented parallel to each other, wherein the battery cells 26A, 26B, 26C, 26D, and 26E are disposed adjacent to and between adjacent pairs of super beam assemblies (16A, 16B), (16B, 16C), (16C, 16D), respectively. The total width of each super beam assembly 16A, 16B, 16C, or 16D can be less than or equal to the width of the battery cell 26A, 26B, 26C, 26D, or 26E to allow for a compact assembly of multiple super beam assemblies and battery cells to be manufactured side by side in the lateral direction (Y axis).

[0170] Fig. 27A schematic perspective view of an example of seven assembled super beam assemblies 16 according to the present disclosure is shown, which hold eight rows of left and right battery cells 26, 26', etc. arranged in parallel rows in a battery pack assembly 10. The super beam assembly 16 is an example of seven parallel super beam assemblies 16, 16' holding a total of thirty-two battery cells 26, 26', etc. A pair of left and right frame shell beams 20 and 20' are longitudinally oriented along the Y direction and are attached to the proximal and distal ends of the vertical panels 18, 18', etc. The left and right coolant channels 30 and 30' are not shown in this illustration and are located between adjacent panels 18 and 18'. The left and right coolant inlet / outlet supply tubes 160, 162 and 160', 162' are respectively disposed inside the frame shell beams 20 and 20' and extend parallel to the Y direction. The left and right inlet / outlet supply tubes 160, 162 and 160' and 162' supply the coolant 70 to the left and right coolant passages 30 and 30' located between the adjacent panels 18 and 18' (see, for example, Figure 4 ).

[0171] Fig.28 A schematic cross-sectional view (section AA) of an example of a super beam assembly 16 holding left and right battery cells 26 and 26' having top and bottom thermal management propagation (TMP) suppression channels 138 and 139, respectively, according to the present disclosure is shown. The top TMP suppression channel 138 may have a rectangular (or circular) cross-section with a lower opening 144 disposed at the bottom side of the top channel 138, which is fluidly connected to the air gap 29 disposed between the left and right panels 18 and 18'. In some examples, the top internal volume 140 (disposed within the TMP suppression channel 138) may be filled with air. Thermal models of transient temperature rise in battery cells adjacent to the battery cell experiencing a TMP event predict that the peak battery cell temperature after 100 seconds can be reduced by approximately 32°C by using the top TMP suppression channel 138. In another example, the top internal volume 140 may be filled with a thermal phase change material (not shown) that absorbs heat during a TMP event and reduces the temperature rise in the adjacent battery cells.

[0172] Still refer to Fig.28, the illustration also shows an example of a bottom TMP suppression channel 139 having a bottom internal volume 141 and an upper opening 145 disposed on the upper side of the bottom channel 139. The top and bottom TMP suppression channels 138, 139 may be attached to the panel flanges 48, 48' and 54, 54', respectively, using upper left and upper right adhesive strips 142, 142', and lower left and lower right adhesive strips 143, 143', respectively. The left and right adhesive strips 142, 142', 143, and 143' may be made of an adhesive material that melts at a relatively low temperature (e.g., 100° C.), which may serve as a "thermal fuse" that melts, separates, and thermally decouples a hot battery cell (e.g., cell 26) that has experienced a thermal management event from an adjacent cold battery cell (e.g., cell 26') to prevent the thermal management from propagating. Moreover, the vertical height and horizontal width of the upper and bottom TMP suppression channels 138 and 139 may be respectively increased (independently or in combination) to increase the thermal resistance path between adjacent left and right battery cells 26 and 26' by providing a longer conductive path between adjacent left and right battery cells 26 and 26'.

[0173] Fig.29A A schematic cross-sectional view (section AA) of an example of a top TMP suppression channel 138 according to the present disclosure is shown. Suppression channel 138 has: a rectangular cross-section; an interior volume 140 (which in some examples may be filled with air or a phase change material); and a lower opening 144.

[0174] Fig.29B A schematic cross-sectional view (section AA) of an example of an alternative design of a TMP suppression channel 146 (top or bottom channel) with four "Z-folds", left and right bellows segments 150 and 150' according to the present disclosure is shown. The four Z-folded left and right bellows segments 150 and 150' are used to increase the total thermal path length between adjacent battery cells, which increases the thermal resistance from one side of the TMP suppression channel 146 to the opposite side of the channel 146. The suppression channel 146 has a bellows-shaped cross-section, an internal volume 148 (which can be filled with air or phase change material in some examples), and a lower opening 144.

[0175] Fig.30A schematic perspective cross-sectional view (section AA) of an example of a top TMP suppression channel 138 having a series of longitudinal slots 170, 170', etc. according to the present disclosure is shown. The TMP suppression channel 138 has: a horizontal longitudinal upper plate 176; a lower opening 144 disposed on the bottom side of the top channel 138; and a central volume 140 that may be hollow or filled with a phase change material (wax, solder, etc.) having a high heat absorption capacity. The series of longitudinal slots 170, 170', etc. are disposed longitudinally along the X-direction, which may be located in the middle of the Y-direction. The purpose of the series of longitudinal slots 170, 170' is to reduce the overall lateral (i.e., in the Y-direction) effective thermal conductivity by inserting a series of openings that reduce or block lateral heat conduction. This is used to reduce the thermal conductivity of the battery cell 26 (see FIG. 2 ) disposed adjacent to the battery cell 26' that is experiencing a TMP event. Figure 4 ) in order to reduce the transient temperature rise in the TMP suppression passage 138. In one example, multiple series (groups) of longitudinal slots 170, 170', etc. may be provided in the longitudinal upper plate 176 of the TMP suppression passage 138. In another example, the longitudinal slots 172, 172', etc. may only partially penetrate the wall thickness of the longitudinal upper plate 176 to maintain the airtight seal of the TMP suppression passage 138.

[0176] Fig.31 A schematic perspective cross-sectional view (section AA) of an example of a top TMP suppression channel 138 having a series of multiple perforations 172, 172' according to the present disclosure is shown. The TMP suppression channel 138 has: a horizontal longitudinal upper plate 176; a lower opening 144 disposed on the bottom side of the top channel 138; and a central volume 140 that may be hollow or filled with a phase change material (wax, solder, etc.) having a high heat absorption capacity. The series of multiple perforations 172, 172', etc. are disposed along the X-direction. The purpose of this series of multiple perforations 172, 172' is to reduce the effective thermal conductivity in the lateral direction (i.e., in the Y-direction) by inserting a series of openings that reduce or block lateral heat conduction, which is used to reduce the battery cell 26 (see FIG. 2 ) disposed adjacent to the battery cell 26' that is experiencing a TMP event. Figure 4 ) in the transient temperature rise. In one example, the perforations may only partially penetrate the wall thickness of the longitudinal upper plate 176, which maintains the airtight seal of the TMP suppression channel 138.

[0177] Fig.32A schematic perspective cross-sectional view (section AA) of an example of a top TMP suppression channel 138 having a central longitudinal recessed groove (or partial slot) 174 according to the present disclosure is shown. The TMP suppression channel 138 has: a horizontal longitudinal upper plate 176; a lower opening 144 disposed on the bottom side of the top channel 138; and a central volume 140 that may be hollow or filled with a phase change material (wax, solder, etc.) having high heat absorption capacity. One or more longitudinal recessed grooves 174 (only one groove 174 is shown) may be disposed along the longitudinal X direction in an intermediate position along the Y direction. The purpose of the one or more recessed grooves 174 is to reduce the lateral effective thermal conductivity (i.e., in the Y direction) by locally reducing the wall thickness of the longitudinal upper plate 176 to reduce lateral heat conduction in the Y direction. This construction is used to reduce the lateral effective thermal conductivity (i.e., in the Y direction) of a conventional battery cell 26 (see Figure 4 ) in the instantaneous temperature rise.

[0178] Fig.33 A schematic perspective view of a battery pack frame housing 8 having a single super beam assembly 16 oriented longitudinally (side to side) in the X direction according to the present disclosure is shown. The frame housing 8 includes parallel side beams 20 and 20' and parallel front and rear beams 6 and 6', respectively. Parallel panels 18 and 18' are oriented longitudinally (side to side) in the X direction. For the super beam assembly 16 oriented longitudinally (side to side) in the X direction, the panels 18 and 18' (and any top and / or bottom structural channels (not shown)) are oriented longitudinally (side to side) in the X direction. When a side beam 20 or 20' is subjected to a lateral force (see FIG. 2 ), the panels 18 and 18' (and any top and / or bottom structural channels (not shown)) are oriented longitudinally (side to side) in the X direction. Figure 1 and 2 ) provides structural support for internal cooling channels (not shown) and battery cells (not shown).

[0179] Fig.34 A schematic perspective view of a battery pack frame housing 8 according to the present disclosure is shown having a single super beam assembly 16 oriented longitudinally (front to back) in the Y direction. Parallel panels 18 and 18' are also oriented longitudinally (front to back) in the Y direction.

[0180] In some examples, the left cooling passage 30 and the right cooling passage 30' (see, for example Figure 4 ) may flow in the same direction (e.g., parallel to the X-axis). In other examples, the coolant 70 may flow in the opposite (i.e., countercurrent) direction (e.g., parallel to the X-axis). For example, the coolant flowing in the left channel 30 may flow in the positive X-direction, while the coolant flowing in the right channel 30' may flow countercurrently in the negative X-direction. Alternatively, the coolant flowing in the left channel 30 may flow in the negative X-direction, while the coolant flowing in the right channel 30' may flow countercurrently in the positive X-direction. The use of a countercurrent cooling circuit may result in more uniform battery temperatures across a group of battery cells 26, 26', etc.

[0181] In some examples, the width of the super beam assembly 16 may be less than or equal to the width of the battery cell 26 , which allows for a compact assembly of adjacent battery cells 26 , 26 ′, etc.

[0182] In some examples, the top TMP suppression channel 138 and / or the bottom TMP suppression channel 139 may be made of a low thermal conductivity ceramic material (e.g., alumina, silicon carbide, or silicon nitride). Alternatively, the TMP suppression channels 138 and / or 139 may be made of a fiber reinforced plastic (FRP) composite material having low thermal conductivity and a high strength / weight ratio. The FRP composite material may have fibers oriented primarily in the longitudinal direction (X direction), such as a one-dimensional FRP.

Claims

1. A multifunctional integrated beam assembly having integrated structural, cooling and lateral elastic compliance functions, comprising: (a) Left panel; (b) right panel; (c) one or more left coolant channel covers; (d) one or more right coolant channel covers; (e) one or more left coolant passages defined by the left panel and one or more left coolant passage cover plates; as well as (f) one or more right coolant passages defined by the right panel and the one or more right coolant passage cover plates; wherein the one or more left coolant channel cover plates are attached to the left panel; wherein the one or more right coolant channel cover plates are attached to the right panel; and Wherein, the left panel is oriented parallel to the right panel.

2. The multifunctional integrated beam assembly according to claim 1, further comprising: a left coolant inlet disposed at a proximal end of the left panel; a left coolant outlet disposed at a distal end of the left panel; a right coolant inlet disposed at a proximal end of the right panel; and A right coolant outlet is disposed at a distal end of the right panel.

3. The multifunctional integrated beam assembly according to claim 1, in, The one or more left coolant passages have a C-shaped cross-section; and Wherein, the one or more right coolant channels have a C-shaped cross section.

4. The multifunctional integrated beam assembly according to claim 1, further comprising: a left battery unit disposed adjacent to the left panel; as well as A right battery unit is disposed adjacent to the right panel.

5. The multifunctional integrated beam assembly according to claim 4, further comprising: a left thermal interface material (TIM) disposed between the left battery cell and the left panel; as well as A right thermal interface material (TIM) is disposed between the right battery cell and the right panel.

6. The multifunctional integrated beam assembly of claim 1, further comprising a top structural channel attached to the left panel and the right panel.

7. The multifunctional integrated beam assembly according to claim 6, wherein: The top structural channel is attached to the left upper extension of the left panel and to the right upper extension of the right panel.

8. The multifunctional integrated beam assembly according to claim 6, wherein: The top structural channel has a T-shaped or M-shaped cross section.

9. The multifunctional integrated beam assembly according to claim 6, further comprising: integrally attached to an upper left flange of the left panel; as well as integrally attached to the right upper flange of the right panel; Wherein, the top structural channel is attached to the left upper flange and the right upper flange.

10. The multifunctional integrated beam assembly according to claim 9, in, the top structural channel adhesively attached to the left upper flange using a left adhesive strip; and Wherein, the top structural channel is adhesively attached to the right upper flange using a right adhesive strip.

Images