Multilayer cover assembly for battery module

Abstract

A battery assembly includes a housing having a bottom wall and a plurality of side walls connected to the bottom wall. The bottom wall includes a midline. The plurality of battery modules are disposed between the midline and one of the plurality of sidewalls. Each of the plurality of battery modules includes an inboard end facing the midline and an outboard end facing one of the plurality of sidewalls. The plurality of battery cells are arranged in each of the plurality of battery modules. The cover assembly is mounted on each of the plurality of battery modules. The cap assembly includes an inner cap member and an outer cap member spaced from and connected to the inner cap member. The outer cover member restricts a flow of gas from the plurality of battery cells to the outer side end.

Description

Technical Field

[0001] The present invention relates to the field of battery assemblies, and more particularly to a multi-layer top cover of a battery module forming a part of a battery assembly. Background Art

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

[0003] When a battery assembly is cycled, that is, undergoes periods of discharge to a load or being charged, heat is generated in the battery cells. If the battery cells are discharged too deeply or recharged improperly, the heat generated can damage the battery. Therefore, it is desirable to provide a battery module having a system that limits the spread of heat through the battery assembly when a chemical reaction begins in a single battery cell. Summary of the invention

[0004] According to a non-limiting example, a battery assembly includes a housing having a bottom wall and a plurality of side walls connected to the bottom wall. The bottom wall includes a center line. A plurality of battery modules are arranged between the center line and one of the plurality of side walls. Each of the plurality of battery modules includes an inner end facing the center line and an outer end facing one of the plurality of side walls. A plurality of battery cells are arranged in each of the plurality of battery modules. A cover assembly is mounted on each of the plurality of battery modules. The cover assembly includes an inner cover member and an outer cover member spaced apart from the inner cover member and connected to the inner cover member. The outer cover member restricts gas from flowing from the plurality of battery cells to the outer end.

[0005] In addition to one or more features described herein, an intermediate cover member is disposed between the inner cover member and the outer cover member, the intermediate cover member including one or more vents.

[0006] In addition to one or more features described herein, the outer cover member is spaced apart from the intermediate cover member.

[0007] In addition to one or more features described herein, a gap having a width of about 10 mm is defined between the intermediate cover member and the outer cover member.

[0008] In addition to one or more features described herein, the intermediate cover member is formed of a temperature resistant electrically insulating material.

[0009] In addition to one or more features described herein, the outer cover member includes a surface extending through each of the plurality of battery cells, the surface including a first end disposed at the inner end, a second end disposed outside the outer end, a first side extending between the first end and the second end, and a second side extending between the first end and the second end, the second side being spaced apart from the first side.

[0010] In addition to one or more features described herein, the outer cover member includes a first end wall extending from a first end of the surface, a first side wall extending from a first side of the surface, and a second side wall extending from a second side of the surface, the first end wall, the first side wall, and the second side wall directing gas from the plurality of battery cells to the second end.

[0011] In addition to one or more features described herein, the inner cover member includes a surface portion extending through each of the plurality of battery cells, the surface portion including a first end portion arranged at the inner end, a second end portion arranged outside the outer end, a first side portion extending between the first end portion and the second end portion, and a second side portion extending between the first end portion and the second end portion, the second side portion being separated from the first side portion by the surface portion.

[0012] In addition to one or more features described herein, the inner cover member includes a first end wall member extending from a first end portion of the surface portion, a second end wall member extending from the first end portion of the surface portion, a first side wall member extending from a first side portion of the surface portion, a second side wall member extending from a second side portion of the surface portion, and the first side wall member and the second side wall member are connected to the first side wall and the second side wall of the outer cover member.

[0013] In addition to one or more features described herein, the second end of the surface includes a connector element connecting the cover member to one of the plurality of side walls of the housing.

[0014] According to a non-limiting example, a vehicle includes a body having a passenger compartment, a drive motor supported in the body, and a rechargeable energy storage system including a battery assembly coupled to the body. The battery assembly includes a housing having a bottom wall and a plurality of side walls connected to the bottom wall. The bottom wall includes a centerline. A plurality of battery modules are arranged between the centerline and one of the plurality of side walls. Each of the plurality of battery modules includes an inner end facing the centerline and an outer end facing one of the plurality of side walls. A plurality of battery cells are arranged in each of the plurality of battery modules. A cover assembly is mounted on each of the plurality of battery modules. The cover assembly includes an inner cover member and an outer cover member spaced apart from the inner cover member and connected to the inner cover member. The outer cover member restricts gas from flowing from the plurality of battery cells to the outer ends.

[0015] In addition to one or more features described herein, an intermediate cover member is disposed between the inner cover member and the outer cover member, the intermediate cover member including one or more vents.

[0016] In addition to one or more features described herein, the outer cover member is spaced apart from the intermediate cover member.

[0017] In addition to one or more features described herein, a gap having a width of about 10 mm is defined between the intermediate cover member and the outer cover member.

[0018] In addition to one or more features described herein, the intermediate cover member is formed of a temperature resistant electrically insulating material.

[0019] In addition to one or more features described herein, the outer cover member includes a surface extending through each of the plurality of battery cells, the surface including a first end disposed at the inner end, a second end disposed outside the outer end, a first side extending between the first end and the second end, and a second side extending between the first end and the second end, the second side being spaced apart from the first side.

[0020] In addition to one or more features described herein, the outer cover member includes a first end wall extending from a first end of the surface, a first side wall extending from a first side of the surface, and a second side wall extending from a second side of the surface, the first end wall, the first side wall, and the second side wall directing gas from the plurality of battery cells to the second end.

[0021] In addition to one or more features described herein, the inner cover member includes a surface portion extending through each of the plurality of battery cells, the surface portion including a first end portion arranged at the inner end, a second end portion arranged outside the outer end, a first side portion extending between the first end portion and the second end portion, and a second side portion extending between the first end portion and the second end portion, the second side portion being separated from the first side portion by the surface portion.

[0022] In addition to one or more features described herein, the inner cover member includes a first end wall member extending from a first end portion of the surface portion, a second end wall member extending from the first end portion of the surface portion, a first side wall member extending from a first side portion of the surface portion, a second side wall member extending from a second side portion of the surface portion, and the first side wall member and the second side wall member are connected to the first side wall and the second side wall of the outer cover member.

[0023] The above features and advantages and other features and advantages of the present disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1is a left side view of a vehicle including a battery assembly housing a plurality of battery modules according to a non-limiting example, the battery module including a multi-layer cover assembly;

[0026] Figure 2 depicts a battery assembly and a plurality of battery modules including a multi-layer cap assembly according to non-limiting examples;

[0027] Figure 3 is an exploded glass view of a multi-layer cover assembly according to a non-limiting example;

[0028] Figure 4 According to non-limiting examples Figure 3 A first end view of the multi-layer cover assembly; and

[0029] Figure 5 yes Figure 4 A second end view of the multi-layer cover assembly. DETAILED DESCRIPTION

[0030] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0031] According to a non-limiting example, the vehicle Figure 1 1. The vehicle 10 is generally indicated at 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20 having a seat 23 located behind an instrument panel 26. A steering controller 30 is disposed between the seat 23 and the instrument panel 26. The steering controller 30 is operated to control the orientation of selected wheels of the plurality of wheels 16. The vehicle 10 includes an electric drive motor 34 that provides power to one or more of the plurality of wheels 16.

[0032] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed within the vehicle body 12 and provides power to the electric drive motor 34. At this point, it should be appreciated that the location of the electric drive motor 34 and the battery assembly 38 may vary. Figure 2 , the battery assembly 38 includes a housing 48, which includes a bottom wall 52 and a plurality of side walls 54. The side walls 54 include a first side wall 58, a second side wall 59, a third side wall 60, and a fourth side wall 61 that together define an interior area 64. The housing 48 includes a centerline 66 that extends between the third side wall 60 and the fourth side wall 61 and is equidistant from the first side wall 58 and the second side wall 59.

[0033] In a non-limiting example, a plurality of battery module members 70 are arranged in the interior area 64. The plurality of battery module members 70 are divided into a first plurality of battery modules 72 arranged between the centerline 66 and the first side wall 58 and a second plurality of battery modules 74 arranged between the centerline 66 and the second side wall 59. In a non-limiting example, each of the plurality of battery module members 70 includes an inner end 80 and an outer end 82 arranged at the centerline 66. In a non-limiting example, the outer end 82 of each of the first plurality of battery modules 72 faces the first side wall 58 of the housing 48, and the outer end 82 of each of the second plurality of battery modules 74 faces the second side wall 59. Each of the plurality of battery module members 70 accommodates a plurality of battery cells, as shown at 86.

[0034] Each of the plurality of battery module members 70 includes a cover assembly 98 that protects the battery cells 86 and reduces the ingress of dust and other objects. Figure 3 In the non-limiting example shown, the cap assembly 98 includes an inner cap member 104, an outer cap member 106, and an intermediate cap member 108. As will be described in further detail herein, in addition to protecting the battery cells 86, the cap assembly 98 contains and directs gases that may be exhausted from the battery cells 86 away from adjacent battery module members in the plurality of battery module members 70 in order to mitigate thermal runaway events.

[0035] Continue to refer to Figure 3 , the inner cover member 104 includes a surface portion 114 having a first end portion 116, a second end portion 118 opposite the first end portion 116, a first side portion 120, and a second side portion 122 opposite the first side portion 120. The first side portion 120 and the second side portion 122 extend between and connect the first end portion 116 and the second end portion 118. The surface portion 114 includes a plurality of openings 126 that can receive and direct outwardly the gas generated by the battery cells 86.

[0036] In a non-limiting example, a first end wall member 128 extends from the first end portion 116, a second end wall member 130 extends from the second end portion 118, a first side wall member 132 extends from the first side portion 120, and a second side wall member 134 extends from the second side portion 122. The first end wall member 128, the second end wall member 130, the first side wall member 132, and the second side wall member 134 are connected to an associated one of the plurality of battery module members 70. To this end, Figure 5 A first plurality of connector members 136 are disposed with the first end wall 128 and a second plurality of connector members 138 are disposed with the second end wall 130. Additional connector members (not separately labeled) may be disposed with the first side wall member 132 and the second side wall member 134.

[0037] Reference Figure 4 and5 , the cover member 106 includes a surface 146 having a first end 148 and a second end 150 opposite the first end 148. The surface 146 also includes a first side 152 and a second side 154 opposite the first side 152. In a non-limiting example, an end wall 160 extends from the first end 148, a first side wall 162 extends from the first side 152, and a second side wall 164 extends from the second side 154.

[0038] In a non-limiting example, the absence of an end wall at the second end 150 creates a channel 166 that directs any gas that may escape from the battery cell 86 away from the inner end 80 and out through the outer end 82, thereby reducing heat accumulation at adjacent battery module components in the plurality of battery module components 70. The channel 166 can direct the gas in one or more directions so as to reduce local temperatures and mitigate thermal runaway events. That is, the cover 106 can include one or more obstructions, channels, and / or recesses that create one or more flow paths that allow gas to quickly escape from the channel 166 without being directed to adjacent modules. In a manner similar to that discussed for the inner cover member 104, the first end 148 can include a first connector element (not shown) and the second end 150 includes a second connector element 170 that secures the outer cover member 106 to an associated one of the plurality of battery module components 70.

[0039] In a non-limiting example, the intermediate cover member 108 is formed of a temperature-resistant electrically insulating material such as mica and includes a surface portion 180 that is substantially similar in size and shape to the surface portion 114 and the surface 146. The surface portion 180 may include a weak area (not separately labeled) that will burst, break, or rupture when exposed to gases of a selected temperature and pressure from the battery cell 86 and passing through the opening 126. The intermediate cover member 108 may also include an opening 188 that allows gas to pass through. In a non-limiting example, a gap 190 exists between the intermediate cover member 108 and the outer cover member 106. The gap 190 has a width of about 10 mm and creates a space that cooperates with the channel 166 to direct the gas away from other battery modules, thereby reducing heat and reducing the chance of thermal runaway initiation.

[0040] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced items. The term "or" means "and / or", unless the context clearly indicates otherwise. References to "an aspect" throughout the specification mean that a particular element (e.g., feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in various aspects.

[0041] When an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

[0042] Unless otherwise indicated herein, all test standards are the most recent standards in effect as of the filing date of the present application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0043] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0044] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from the scope thereof. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the disclosure without departing from the essential scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery assembly comprising: a housing including a bottom wall and a plurality of side walls connected to the bottom wall, the bottom wall including a centerline; a plurality of battery modules disposed between the centerline and one of the plurality of side walls, each of the plurality of battery modules including an inner end facing the centerline and an outer end facing one of the plurality of side walls; a plurality of battery cells arranged in each of the plurality of battery modules; as well as A cap assembly is mounted on each of the plurality of battery modules, the cap assembly including an inner cap member and an outer cap member spaced apart from and connected to the inner cap member, the outer cap member restricting gas flow from the plurality of battery cells to the outer side ends.

2. The battery assembly according to claim 1, further comprising an intermediate cover member disposed between the inner cover member and the outer cover member, the intermediate cover member comprising one or more vents.

3. The battery assembly according to claim 2, wherein: The outer cover member is spaced apart from the intermediate cover member. 4 . The battery assembly according to claim 3 , further comprising a gap having a width of about 10 mm defined between the intermediate cover member and the outer cover member.

5. The battery assembly according to claim 2, wherein: The intermediate cover member is formed of a temperature-resistant electrically insulating material.

6. The battery assembly according to claim 1, wherein: The outer cover member includes a surface extending through each of the plurality of battery cells, the surface including a first end arranged at the inner end, a second end arranged outside the outer end, a first side extending between the first end and the second end, and a second side extending between the first end and the second end, the second side being spaced apart from the first side.

7. The battery assembly according to claim 6, wherein: The cover member includes a first end wall extending from a first end of the surface, a first side wall extending from a first side of the surface, and a second side wall extending from a second side of the surface, the first end wall, the first side wall, and the second side wall directing gas from the plurality of battery cells toward the second end.

8. The battery assembly according to claim 7, wherein: The inner cover member includes a surface portion extending through each of the plurality of battery cells, the surface portion including a first end portion arranged at the inner end, a second end portion arranged outside the outer end, a first side portion extending between the first end and the second end, and a second side portion extending between the first end portion and the second end portion, the second side portion being spaced apart from the first side portion by the surface portion.

9. The battery assembly according to claim 8, wherein: The inner cover member includes a first end wall member extending from a first end portion of the surface portion, a second end wall member extending from a first end portion of the surface portion, a first side wall member extending from a first side portion of the surface portion, and a second side wall member extending from a second side portion of the surface portion, and the first side wall member and the second side wall member are connected to the first side wall and the second side wall of the outer cover member.

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

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