Cooling assembly for battery pack

Abstract

A cooling assembly for a battery pack having at least one cylindrical battery cell, the cooling assembly comprising a manifold having an inlet line for receiving a coolant and an outlet line for discharging the coolant, a solder strip header, a solder strip, and a separator, and a solder strip header connected to the manifold and having an inlet line in fluid communication with the manifold and a return line in fluid communication with the outlet line, the solder strip in contact with the cylindrical battery cells and defining an outflow channel and a return channel therethrough, where the solder strip is connected to the solder strip header and the outflow channel is in fluid communication with the feed line, and the return line is in fluid communication with the return line. And the backflow channel is in fluid communication with the backflow pipeline, and the partition plate is arranged between the manifold and the solder strip header.

Description

Technical Field

[0001] The present disclosure relates to a cooling assembly for a battery pack. More specifically, the present disclosure relates to a cooling assembly for a ribbon-cooled battery pack. Background Art

[0002] Electric vehicles and hybrid vehicles use high-voltage battery systems that include multiple battery cells. These electric and hybrid vehicles typically require multiple battery cells to provide sufficient power to meet the vehicle's power and energy needs. The battery cells are typically located under the vehicle body in the middle between the front and rear wheels.

[0003] Battery cells, particularly the high voltage types described above, generate significant amounts of heat during sustained operation. Over time, the heat generated can degrade the efficiency and overall structural integrity of the battery pack. Therefore, thermal management systems are used to closely regulate the temperature of the battery pack. In one type of thermal management system, a heat transfer fluid is circulated between fins or ribbons spaced between the battery cells. While effective, there is a need in the art for an improved coolant system design. Summary of the invention

[0004] The present invention provides a cooling assembly for a battery pack, which has at least one cylindrical battery cell. The cooling assembly includes a manifold, a ribbon header and a ribbon, the manifold having an inlet pipeline for receiving a coolant and an outlet pipeline for discharging the coolant, the ribbon header connected to the manifold and having a ribbon feeder in fluid communication with the inlet pipeline and a ribbon return pipeline in fluid communication with the outlet pipeline, and the ribbon contacts the cylindrical battery cell and defines an outflow channel and a return channel passing through the ribbon. The ribbon is connected to the ribbon header, the outflow channel is in fluid communication with the ribbon feeder, and the return channel is in fluid communication with the ribbon return pipeline. A partition is provided between the manifold and the ribbon header. The coolant flows from the inlet pipeline of the manifold to the ribbon feeder of the ribbon header to the outflow channel of the ribbon to cool the cylindrical battery cell, and the coolant flows from the outflow channel to the return channel and passes through the ribbon header to the ribbon return pipeline of the outlet pipeline of the manifold.

[0005] In one aspect, the ribbon is connected to the front surface of the ribbon header.

[0006] In another aspect, the manifold is connected to the ribbon header by at least one mechanical fastener extending parallel to the front surface and through the bulkhead to prevent forces from being transferred to the ribbons during assembly of the manifold to the ribbon header.

[0007] In another aspect, the front surface includes a slot defined by parallel flanges extending from the front surface, and the proximal end of the solder ribbon is disposed within the slot.

[0008] On the other hand, the solder ribbon feed port is arranged in the groove at the front surface, and the solder ribbon reflow port is arranged in the groove at the front surface, the solder ribbon feed port is connected with the solder ribbon feed line and the outflow channel of the solder ribbon, and the solder ribbon reflow port is connected with the solder ribbon reflow pipeline and the solder ribbon reflow channel.

[0009] In another aspect, a vertical feed line and a first connecting line are disposed within the ribbon header, wherein the vertical feed line communicates with an inlet line of the manifold, and the first connecting line communicates between the vertical feed line and the ribbon feed line.

[0010] In another aspect, a vertical return line and a second connecting line are disposed within the ribbon header, wherein the vertical return line communicates with the outlet line of the manifold and the second connecting line communicates between the vertical return line and the ribbon return line.

[0011] In another aspect, the manifold is constructed of a composite material.

[0012] In another aspect, a bulkhead includes a frame having a plurality of windows and a gasket disposed along edges of the plurality of windows to seal the manifold to the ribbon header.

[0013] On the other hand, the inlet pipeline includes a feed port extending to the bottom surface of the manifold, and the outlet pipeline includes a return port extending to the bottom surface of the manifold, wherein the weld ribbon header includes a weld ribbon header inlet and a weld ribbon header outlet, and the weld ribbon header inlet and the weld ribbon header outlet are both arranged in the top surface of the weld ribbon header, the weld ribbon header inlet is fluidly connected with the feed port and the weld ribbon feed line, and the weld ribbon header outlet is fluidly connected with the return port and the weld ribbon return pipeline.

[0014] In another aspect, one window of the plurality of windows in the baffle is aligned with the feed port and the ribbon manifold inlet, and another window of the plurality of windows is aligned with the reflow port and the ribbon manifold outlet.

[0015] In another embodiment, the present invention provides a battery pack. The battery pack includes a battery tray, a plurality of cylindrical battery cells supported on the battery tray, and a cooling assembly. The cooling assembly includes a manifold, a plurality of ribbon headers, and a plurality of ribbons, the manifold having an inlet line for receiving a coolant and an outlet line for discharging the coolant, the inlet line having a plurality of feed ports extending to the bottom surface of the manifold, and the outlet line having a plurality of return ports extending to the bottom surface of the manifold, each of the plurality of ribbon headers is connected to the bottom surface of the manifold and each has a ribbon feed line in fluid communication with one of the feed ports and a ribbon return line in fluid communication with one of the return ports, and the plurality of ribbons are in contact with the plurality of cylindrical battery cells and each ribbon defines an outflow channel and a return channel passing through the ribbon. Each of the plurality of ribbons is connected to a corresponding one of the plurality of ribbon headers, and each outflow channel is in fluid communication with a ribbon feed line of a corresponding one of the plurality of ribbon headers, and each return channel is in fluid communication with a ribbon return line of a corresponding one of the plurality of ribbon headers. A baffle is disposed between the manifold and the plurality of ribbon headers, the baffle being configured to seal the manifold to the plurality of ribbon headers. A coolant flows from an inlet line of the manifold to the ribbon feed lines of the plurality of ribbon headers via a feed port, and for each of the plurality of ribbon headers, the coolant flows to an outflow channel of a corresponding one of the plurality of ribbons to cool the cylindrical battery cells, and the coolant flows from the outflow channel to the return channel and passes through the ribbon return lines of the plurality of ribbon headers to an outlet line of the manifold via a return port.

[0016] In one aspect, each of the plurality of solder ribbons is connected to a front surface of a corresponding one of the plurality of solder ribbon headers.

[0017] In another aspect, the manifold is connected to the plurality of ribbon headers by a plurality of mechanical fasteners each extending parallel to the front surface and through the bulkhead, thereby preventing forces from being transmitted to the plurality of ribbons during assembly of the manifold to the plurality of ribbon headers.

[0018] In another aspect, each front surface includes a slot defined by parallel flanges extending from the front surface, and a proximal end of one of the plurality of solder ribbons is disposed within each slot.

[0019] On the other hand, a ribbon feed port is disposed in a narrow groove at the front surface, and a ribbon reflow port is disposed in the narrow groove at the front surface, the ribbon feed port is connected to a ribbon feed line and an outflow channel of one of a plurality of ribbons, and the ribbon reflow port is connected to a ribbon reflow line and a reflow channel of one of a plurality of ribbons.

[0020] In another aspect, a vertical feed line and a first connecting line are disposed within each of the plurality of ribbon headers, wherein the vertical feed line communicates with an inlet line of the manifold, and the first connecting line communicates between the vertical feed line and the ribbon feed line.

[0021] In another aspect, a vertical return line and a second connecting line are disposed within each of the plurality of ribbon headers, wherein the vertical return line communicates with the outlet line of the manifold and the second connecting line communicates between the vertical return line and the ribbon return line.

[0022] In another aspect, the manifold is constructed of a composite material.

[0023] The present invention provides a battery thermal management system for cylindrical battery cells. The battery thermal management system includes a recovery tank for storing coolant, a pump connected to the recovery tank fluid to pump the coolant, and a cooling assembly. The cooling assembly includes a manifold, a ribbon header, a ribbon, a baffle and a heat exchanger, the manifold having an inlet pipeline connected to the pump fluid for receiving the coolant and an outlet pipeline for discharging the coolant; the ribbon header is connected to the manifold and has a feeder connected to the inlet pipeline fluid and a return pipeline connected to the outlet pipeline fluid, the ribbon contacts the cylindrical battery cell and defines an outflow channel and a return channel passing through the ribbon, wherein the ribbon is connected to the ribbon header, and the outflow channel is connected to the feeder fluid, and the return channel is connected to the return pipeline fluid, the baffle is arranged between the manifold and the ribbon header, and the heat exchanger is connected to the outlet pipeline of the manifold and the recovery tank fluid. The coolant is pumped by a pump to the inlet line of the manifold, the coolant flows from the inlet line of the manifold to the feed line of the outflow channel of the ribbon header to the ribbon to cool the cylindrical battery cells, and the coolant flows from the outflow channel to the return channel and passes through the ribbon header to the return line of the outlet line of the manifold, and then flows from the outlet line to the heat exchanger and then to the recovery tank.

[0024] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0026] Figure 1 is a schematic diagram of an exemplary motor vehicle having a battery pack with a cooling assembly according to the principles of the present disclosure;

[0027] Figure 2 is a top perspective view of the cooling assembly;

[0028] Figure 3is a top perspective exploded view of the cooling assembly;

[0029] Figure 4 is along Figure 2 A cross-sectional view of the cooling assembly viewed in the direction of arrow 4-4;

[0030] Figure 5 is along Figure 2 A cross-sectional view of the cooling assembly viewed in the direction of arrow 5-5;

[0031] Figure 6 is along Figure 2 A cross-sectional view of the cooling assembly viewed in the direction of arrow 6-6;

[0032] Figure 7 is along Figure 2 A cross-sectional view of the cooling assembly viewed in the direction of arrow 7-7; and

[0033] Figure 8 is a top perspective view of a baffle in a cooling assembly. DETAILED DESCRIPTION

[0034] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0035] refer to Figure 1 , a cooling assembly 10 for a battery pack 12 according to the principles of the present disclosure is shown. The cooling assembly 10 is configured to provide cooling to the battery pack 12, which will be described in more detail below. The battery pack 12 is shown together with an exemplary vehicle 14. Preferably, the vehicle 14 is an electric vehicle or a hybrid vehicle having wheels 16 driven by a motor / inverter 18. The motor / inverter 18 receives power from the battery pack 12. Although the vehicle 14 is shown as a passenger road vehicle, it should be understood that the cooling assembly 10 and the battery pack 12 can be used with various other types of vehicles. For example, the cooling assembly 10 and the battery pack 12 can be used in a marine vehicle (such as a ship) or an aviation vehicle (such as a drone or a passenger aircraft). In addition, the cooling assembly 10 and the battery pack 12 can be used as a stationary power source that is separate and independent from the vehicle.

[0036] The battery pack 12 generally includes a battery tray 20 that is connected to the vehicle 14. The battery tray 20 provides structural support for one or more battery cells 22 (only one of which is shown) arranged within the battery pack 12. The battery cells 22 are preferably cylindrical lithium-ion battery cells. However, it should be understood that any type of battery cell 22 may be used as long as the battery cell 22 is compatible with the cooling assembly 10.

[0037] Reference now Figure 2 and Figure 3, the cooling assembly 10 is shown relative to an exemplary battery cell of the battery cell 22. The cooling assembly 10 is configured to circulate a coolant 24 therethrough so as to cool the battery cell 22 via heat transfer. The cooling assembly 10 forms part of a larger battery thermal management system 26, which generally includes a pump 28, a heat exchanger 30, and a recovery tank 32. The battery thermal management system 26 may include various other components, including temperature and humidity sensors, valves, and electronic controllers, without departing from the scope of the present disclosure. In general, the pump 28 is in fluid communication with the recovery tank 32 and pumps the coolant 24 from the recovery tank 32 to the cooling assembly 10. The cooling assembly 10 delivers the coolant 24 to the battery cell 22 to cool the battery cell 22. The coolant 24 is then returned from the cooling assembly 10 and delivered to the heat exchanger 30. The heat exchanger 30 removes heat from the coolant 24, for example, using a liquid to air heat exchanger with a fan, but other types of heat exchangers may also be used. The coolant 24 flows back to the recovery tank 32.

[0038] The cooling assembly 10 includes a manifold 40, one or more ribbon headers 42, one or more ribbons 44, and a separator 46. The manifold 40 is connected to the ribbon header 42 via one or more mechanical fasteners 48. Each ribbon 44 is individually connected to a corresponding ribbon header 42. The separator 46 is disposed between the manifold 40 and the ribbon header 42. Each of these components will be described in more detail below.

[0039] The manifold 40 is configured to deliver the coolant 24 received from the pump 28 to each of the ribbon headers 42. The manifold is made of a composite material, such as glass-filled nylon. Various other composite materials may be used and selected to reduce weight and be compatible with the coolant 24. The manifold 40 includes an inlet 50 and an outlet 52 disposed in an end 54 of the manifold 40. The inlet 50 is connected to an inlet line 56 ( Figure 4 ) is connected to the outlet 52 and to an outlet line 58 ( Figure 6 ) is connected. Preferably, the inlet line 56 and the outlet line 58 are through holes drilled in the manifold and extend parallel to each other. The end 60 of the inlet line 56 opposite to the inlet 50 and the end 62 of the outlet line 58 opposite to the outlet 52 can each be connected to an additional pump, a heat exchanger and a recovery tank, or can be sealed with a plug 64.

[0040] refer to Figure 4 , the inlet line 56 includes one or more feed ports 66 extending through a bottom surface 68 of the manifold 40. The number of feed ports 66 corresponds to the number of ribbon headers 42 and the number of ribbons 44. Thus, in the example provided, there are four feed ports 66. However, it should be understood that one or more ribbon headers 42 and ribbons 44 may be employed.

[0041] refer to Figure 6 , the outlet line 58 includes one or more return ports 70 extending through the bottom surface 68 of the manifold 40. The number of return ports 70 corresponds to the number of ribbon headers 42 and the number of ribbons 44.

[0042] Back to Figure 3 , the ribbon headers 42 are configured to deliver coolant 24 received from the manifold 40 to corresponding ribbons 44. The ribbon headers 42 are connected to the manifold 40 at the bottom surface 68 of the manifold 40. Each ribbon header 42 is identical, so only one is described. Preferably, the ribbon headers 42 are made of die cast metal. The ribbon headers 42 include a ribbon header inlet 72 disposed on an upper surface 74 of the ribbon header 42. The ribbon header inlet 72 is in fluid communication with the feed port 66 of the manifold 40 for receiving the coolant 24. The ribbon header outlet 76 is disposed on the upper surface 74 of the ribbon header 42. The ribbon header outlet 76 is in fluid communication with the return port 70 of the manifold 40 for discharging the coolant 24 back to the manifold 40.

[0043] refer to Figure 5 and Figure 7 The ribbon header inlet 72 is connected to a vertical feed line 78 extending through the entire height (in the Z direction) of the ribbon header 42. The ribbon header outlet 76 is connected to a vertical feed line 78 extending through the entire height (in the Z direction) of the ribbon header 42. Figure 1 and Figure 3 The vertical return line 80 (Z direction shown) Figure 6 Preferably, the vertical feed line 78 and the vertical return line 80 are through holes drilled in the ribbon header 42 and extend parallel to each other.

[0044] The ribbon header 42 also includes a ribbon feeder 82 ( Figure 5 ) and solder ribbon reflow line 84 ( Figure 7 The ribbon feed line 82 and the ribbon return line 84 are both disposed between the vertical feed line 78 and the vertical return line 80. The ribbon feed line 82 is connected to the vertical feed line 78 via a first connecting line 86 ( Figure 5 ). The first connection line 86 is a through hole drilled into the side 88 of the ribbon header 42, through the vertical feed line 78 and to the ribbon feed line 82. One of the plugs 64 is provided at the end of the first connection line 86 to seal the first connection line 86 from the external environment. Similarly, the ribbon return line 84 is connected via a second connection line 90 ( Figure 7 ) is in communication with the vertical return line 80. The second connection line 90 is a through hole drilled into the side 92 of the ribbon header 42, passing through the vertical return line 80 and reaching the ribbon return line 84. One of the plugs 64 is provided at the end of the second connection line 90 to seal the second connection line 90 from the external environment.

[0045] The ribbon feed line 82 is connected to the ribbon feed port 96 ( Figure 5 ). The ribbon reflow line 84 is in communication with a ribbon reflow port 100 disposed on the front surface 98. The ribbon feed port 96 and the ribbon reflow port 100 are both disposed within a slot 102 formed by parallel flanges 104 extending from the front surface 98. The slot 102 is sized to receive the ribbon 44 therein.

[0046] Continue to refer Figure 5 and Figure 7 The welding ribbon 44 is configured to circulate the coolant 24 to the battery cell 22 so as to transfer heat from the battery cell 22 to the coolant 24. Preferably, the welding ribbon 44 is made of aluminum and has an elongated wavy shape corresponding to the outer surface of the battery cell 22 (see Figure 2 ). The solder ribbon 44 is bifurcated along the length of the solder ribbon 44, and an outflow channel 106 is provided in the solder ribbon 44 and is located below a separate return channel 108 arranged in the solder ribbon 44. The outflow channel 106 is connected to the return channel 108 at the distal end (not shown) of the solder ribbon 44. Therefore, the coolant 24 can travel along the entire length of the solder ribbon 44 to the distal end via the outflow channel 106 and return to the entire length of the solder ribbon 44 via the return channel 108. When the coolant 24 travels through the solder ribbon 44, the battery cells 22 in contact with the solder ribbon 44 exchange heat with the coolant 24. The proximal end 109 of the solder ribbon 44 is disposed in the narrow groove 102 of the solder ribbon manifold 42, so that the outflow channel 106 is connected to the solder ribbon feed port 96, and the return channel 108 is connected to the solder ribbon return port 100. Preferably, the solder ribbon 44 is welded to the solder ribbon manifold 42.

[0047] Now turn to Figure 8 , the bulkhead 46 is configured to seal the manifold 40 to the ribbon header 42. The bulkhead 46 includes a frame 110. Preferably, the frame 110 is made of metal, such as steel. A plurality of windows 112 are disposed within the frame 110. The windows 112 are aligned with the ribbon header inlet 72 and the ribbon header outlet 76 and the feed port 66 and the return port 70 of the manifold 40. In one aspect, the windows 112 are larger than the ribbon header inlet 72, the ribbon header outlet 76, the feed port 66, and the return port 70 to allow for easier alignment during assembly. A plurality of gaskets 114 are connected to the frame 110 around the edges of the windows 112. The gaskets 114 seal the feed port 66 and the ribbon header inlet 72 from the return port 70 and the ribbon header outlet 76. The gaskets 114 may be paper gaskets, edge bonded gaskets, or room temperature vulcanized (RTV) gaskets.

[0048] Combined with reference Figure 2-Figure 8During operation, the coolant 24 is pumped from the pump 28 to the inlet line 56 of the manifold 40. The coolant 24 is then delivered to each ribbon header 42 via the feed port 66. Within a given ribbon header 42, the coolant 24 is received in the vertical feed line 78, the coolant 24 is delivered to the ribbon feed line 82 via the first connecting line 86, and then continues to the ribbon 44. The coolant 24 passes through the ribbon 44 in the outflow channel 106 to the battery cell 22 and returns via the return channel 108. As the coolant 24 travels through the ribbon 44, the battery cell 22 in contact with the ribbon 44 exchanges heat with the coolant 24. The coolant 24 is returned to the ribbon return line 84 and delivered to the vertical return line 80 via the second connecting line 90. The coolant 24 is then connected to the outlet line 58 of the manifold 40 via the return port 70. The coolant 24 is then transferred to the heat exchanger 30 and returned to the recovery tank 32 .

[0049] Back to Figure 2-Figure 3 , the cooling assembly 10 is assembled in the Z direction using mechanical fasteners 48 to secure the manifold 40 to the ribbon header 42. The mechanical fasteners 48 are arranged parallel to the front surface 98 of the ribbon header 42 and perpendicular to the bottom surface 68 of the manifold 40 and the upper surface 74 of the ribbon header 42. Therefore, any forces applied during the assembly process are in the Z direction (i.e., the vertical direction relative to the vehicle 14 and the battery pack 12), and these forces are not transmitted to the ribbon 44, thereby minimizing the ribbon misalignment or ribbon offset during the manufacture of the cooling assembly 10. Compared with conventional techniques, the arrangement of the manifold 40, the ribbon header 42, the ribbon 44, the partition 46, and the specific arrangement of the fluid lines and channels simplify assembly and improve the fluid flow of the coolant 24 therethrough. The cooling assembly 10 of the present disclosure also allows for easier maintenance of the seals of the partition 46, and uses torque readings on the mechanical fasteners 48 to prevent errors.

[0050] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to fall within the scope of the present disclosure. These variations should not be regarded as departing from the spirit and scope of the present disclosure.

Claims

1. A cooling assembly for a battery pack having at least one cylindrical battery cell, the cooling assembly comprising: a manifold having an inlet line for receiving a coolant and an outlet line for discharging the coolant; a ribbon header connected to the manifold and having a ribbon feed line in fluid communication with the inlet line and a ribbon return line in fluid communication with the outlet line; a solder ribbon contacting the cylindrical battery cell and defining an outflow channel and a return channel therethrough, wherein the solder ribbon is connected to the solder ribbon header and the outflow channel is in fluid communication with the solder ribbon feed line and the return channel is in fluid communication with the solder ribbon return line; and a partition disposed between the manifold and the ribbon header, The coolant flows from the inlet line of the manifold to the ribbon feed line from the ribbon header to the outflow channel of the ribbon to cool the cylindrical battery cells, and the coolant flows from the outflow channel to the return channel and passes through the ribbon return line from the ribbon header to the outlet line of the manifold.

2. The cooling assembly according to claim 1, wherein: The solder ribbon is connected to the front surface of the solder ribbon header.

3. The cooling assembly according to claim 2, wherein: The manifold is connected to the ribbon header by at least one mechanical fastener extending parallel to the front surface and through the partition to prevent forces from being transmitted to the ribbons during assembly of the manifold to the ribbon header.

4. The cooling assembly according to claim 3, wherein: The front surface includes a slot defined by parallel flanges extending from the front surface, and the proximal end of the solder ribbon is disposed within the slot.

5. The cooling assembly according to claim 4 further includes a solder ribbon feed port arranged in the narrow groove at the front surface and a solder ribbon reflow port arranged in the narrow groove at the front surface, the solder ribbon feed port is connected to the solder ribbon feed line and the outflow channel of the solder ribbon, and the solder ribbon reflow port is connected to the solder ribbon reflow pipeline and the reflow channel of the solder ribbon.

6. The cooling assembly according to claim 4, further comprising a vertical feed line and a first connecting pipeline disposed in the welding ribbon header, wherein: The vertical feed line is in communication with an inlet line of the manifold, and the first connecting line is in communication between the vertical feed line and the ribbon feed line.

7. The cooling assembly according to claim 6, further comprising a vertical return line and a second connecting line disposed in the welding ribbon header, wherein: The vertical return line is in communication with an outlet line of the manifold, and the second connecting line is in communication between the vertical return line and the ribbon return line.

8. The cooling assembly according to claim 1, wherein: The manifold is constructed of a composite material.

9. The cooling assembly according to claim 1, wherein: The bulkhead includes a frame having a plurality of windows and a gasket disposed along edges of the plurality of windows to seal the manifold to the ribbon header.

10. The cooling assembly according to claim 9, wherein: The inlet pipeline includes a feed port extending to the bottom surface of the manifold, and the outlet pipeline includes a return port extending to the bottom surface of the manifold, wherein the weld ribbon header includes a weld ribbon header inlet and a weld ribbon header outlet, and the weld ribbon header inlet and the weld ribbon header outlet are both arranged in the top surface of the weld ribbon header, the weld ribbon header inlet is fluidly connected with the feed port and the weld ribbon feed line, and the weld ribbon header outlet is fluidly connected with the return port and the weld ribbon return pipeline.

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