Cooling system manifold for battery module

Abstract

A cooling system manifold for a battery module having at least one battery cell and at least one temperature regulating component having a flow path with a feed port and a return port to receive and discharge a coolant. A cooling system manifold is removably attached to the battery module for supplying coolant to and / or removing coolant from the temperature regulating component, and the cooling system manifold is formed by a first portion and a second portion, respectively, connected together and forming an internal coolant flow channel. The first portion has a passage feature for removing coolant from or introducing coolant into the coolant flow channel, and the second portion has an engagement opening providing a coolant flow path between the coolant flow channel and the temperature regulating component. The manifold has an integrated seal that sealingly engages the opening and the temperature regulating component, a counter bore that prevents removal, and a rear stop that limits movement of the seal.

Description

Technical Field

[0001] The present disclosure relates to a cooling system manifold for a battery module that is part of a rechargeable energy storage system. More specifically, the present disclosure relates to a removable manifold with an integral seal for providing a heat transfer fluid flow to a cooled battery module.

[0002] Electric vehicles and hybrid vehicles use a high-voltage rechargeable energy storage system that includes multiple battery modules, each of which includes multiple battery cells. These electric and hybrid vehicles typically require several battery cells to provide enough power to meet the vehicle power and energy requirements. The battery modules are typically located under the vehicle body midway between the front and rear wheels.

[0003] Battery cells, especially the high voltage type described above, generate a large amount of heat during continuous operation. Over time, the heat generated may reduce the efficiency and overall structural integrity of the battery module. Therefore, a thermal management system is used to closely regulate the temperature of the battery module. In one type of thermal management system, a heat transfer fluid circulates through a temperature regulating component, such as a strip or cooling plate spaced between the battery cells. The cooling system has a sealing element that is integrated into the strip or cooling plate and is not repairable. Although effective, there is a need in the art for an improved coolant system design to allow for online rework or repair of the cooling system. Summary of the invention

[0004] A cooling system manifold for a battery module is provided. The battery module has at least one battery cell and at least one temperature regulating component, the temperature regulating component having a flow path, the flow path having a feed port for receiving a coolant and a return port for discharging the coolant. The cooling system manifold includes a supply manifold that can be attached to the battery module for supplying coolant to at least one temperature regulating component in the battery module, and the cooling system manifold has a first supply manifold part that is respectively formed and connected to the second part of the supply manifold to form an internal supply channel. The first part of the supply manifold has a supply port for introducing coolant into the internal supply channel, and the second part of the supply manifold has an outlet for introducing coolant from the internal supply channel into the feed port. The first seal is disposed in the outlet and has a first section that seals the outlet and a second section that can seal the feed port. The cooling system manifold includes a removable manifold that can be attached to the battery module, the removable manifold is used to remove coolant from at least one temperature regulating component in the battery module, and the cooling system manifold has a first removal manifold part that is respectively formed and connected to the second part of the removal manifold to form an internal removal channel. The first portion of the removal manifold has a removal port for directing coolant out of the internal removal passage, and the second portion of the removal manifold has an inlet for directing coolant from the return port into the internal removal passage. A second seal is disposed in the inlet and has a first section that seals the inlet and a second section that can seal the return port.

[0005] In one aspect, the supply manifold second portion includes a plurality of attachment sections that are attached to the battery module by removable fasteners, and the removal manifold second portion has a plurality of attachment sections that are attached to the battery module by removable fasteners.

[0006] In another aspect, the cooling system manifold includes compression limiters disposed in the supply manifold second portion attachment section and the removal manifold second portion attachment section. The compression limiters limit compression of the supply manifold attachment section by removable fasteners that attach the supply manifold to the battery module and limit compression of the removal manifold attachment section by removable fasteners that attach the removal manifold to the battery module.

[0007] On the other hand, the second portion attachment section of the supply manifold has two alignment holes, which accept the insertion of alignment pins on the battery module and align the supply manifold with the battery module, and the second portion attachment section of the removal manifold has two alignment holes, which accept the insertion of alignment pins on the battery module and align the removal manifold with the battery module.

[0008] In another aspect, a coolant supply line has a supply attachment bracket and supplies coolant to a supply manifold, and a coolant return line has a return attachment bracket and removes coolant from a removal manifold. A first portion of the supply manifold has a removable fastener engagement opening adjacent to the supply port, and a first portion of the removal manifold has a removable fastener engagement opening adjacent to the removal port. The coolant supply line is attached to the supply port by the supply attachment bracket, the supply attachment bracket is attached to the supply manifold by a fastener in the supply manifold fastener engagement opening, and the coolant return line is attached to the removal port by the return attachment bracket, and the return attachment bracket is attached to the removal manifold by a fastener in the removable manifold fastener engagement opening.

[0009] In another aspect, the first supply manifold portion and the second supply manifold portion are injection molded separately and include a coupling element that connects the first supply manifold portion to the second supply manifold portion and forms a seal that retains coolant in the internal supply passage, the first seal is disposed in the outlet before or after the first supply manifold portion and the second supply manifold portion are connected together, the first removal manifold portion and the second removal manifold portion are injection molded separately and include a coupling element that connects the first removal manifold portion to the second removal manifold portion and forms a seal that retains coolant in the internal removal passage, and the second seal is disposed in the inlet before or after the first removal manifold portion and the second removal manifold portion are connected together.

[0010] On the other hand, the supply manifold first portion includes a rear stop formed during injection molding and aligned with the outlet, wherein the supply manifold rear stop limits movement of the first seal in the outlet toward the supply manifold first portion, and the removal manifold first portion includes a rear stop formed during injection molding and aligned with the inlet, and wherein the removal manifold rear stop limits movement of the second seal in the inlet toward the removal manifold first portion.

[0011] On the other hand, the outlet includes an inner surface having a step feature formed in the injection molding, a first section of the first seal has an outer diameter, the outer diameter contacts the outlet step feature and prevents the first seal from being removed from the outlet and leaving the first portion of the supply manifold, and the supply manifold can be removed from the battery module with the first seal remaining in the supply manifold, and the inlet includes an inner surface having a step feature formed in the injection molding, a first section of the second seal has an outer diameter, the outer diameter contacts the inlet step feature and prevents the second seal from being removed from the inlet of the first portion of the removal manifold and leaving the first portion of the removal manifold, and the removable manifold can be removed from the battery module with the second seal remaining in the removal manifold.

[0012] In another embodiment, a cooling system manifold for a battery module is provided. The battery module has at least one battery cell and at least one temperature regulating component, the temperature regulating component having a flow path, the flow path having a feed port for receiving a coolant and a return port for discharging the coolant. The cooling system manifold includes a manifold that can be attached to the battery module for supplying coolant to at least one temperature regulating component in the battery module and removing coolant from at least one temperature regulating component in the battery module, and the cooling system manifold has a first manifold portion that is formed separately and connected to a second portion of the manifold, and forms an internal supply channel and an internal removal channel. The first portion of the manifold has a supply port and a removal port, the supply port introduces the coolant into the internal supply channel, the removal port guides the coolant out of the internal removal channel, and the second portion of the manifold has an outlet and an inlet, the outlet introduces the coolant from the internal supply channel into the feed port, and the inlet introduces the coolant from the return port into the internal removal channel. The first seal is disposed in the outlet and has a first section that seals the outlet and a second section that can seal the feed port. The second seal is disposed in the inlet and has a first section that seals the inlet and a second section that can seal the return opening.

[0013] In one aspect, the manifold second portion has a plurality of attachment sections that are attached to the battery module via removable fasteners.

[0014] In another aspect, the cooling system manifold includes a compression limiter disposed in the attachment section. The compression limiter limits compression of the attachment section via a removable fastener that attaches the manifold to the battery module.

[0015] In another aspect, the attachment section has two alignment holes that receive insertion of alignment pins on the battery module and align the manifold with the battery module.

[0016] In another aspect, a coolant supply line has a supply attachment bracket and supplies coolant to a manifold, and a coolant return line has a return attachment bracket and removes coolant from the manifold. The manifold first portion has a removable fastener engagement opening adjacent to the supply port, and the manifold first portion has a removable fastener engagement opening adjacent to the removal port. The coolant supply line is attached to the supply port by the supply attachment bracket, which is attached to the manifold by a fastener in the fastener engagement opening adjacent to the supply port, and the coolant return line is attached to the removal port by the return attachment bracket, which is attached to the manifold by a fastener in the fastener engagement opening adjacent to the removal port.

[0017] In another aspect, the first manifold portion and the second manifold portion are injection molded separately and include a coupling element that connects the first manifold portion to the second manifold portion and forms a seal that retains coolant in the internal supply passage and the internal removal passage, the first seal being disposed in the outlet before or after the first manifold portion and the second manifold portion are connected together, and the second seal being disposed in the inlet before or after the first manifold portion and the second manifold portion are connected together.

[0018] In another aspect, the manifold first portion includes a back stop formed during injection molding, the back stop being aligned with the outlet and the inlet, wherein the back stop limits movement of the first seal in the outlet toward the first portion and limits movement of the second seal in the inlet toward the first portion.

[0019] On the other hand, the outlet includes an inner surface having a step feature formed during injection molding, a first section of the first seal having an outer diameter that contacts the outlet step feature and prevents the first seal from being removed from the outlet and away from the first portion, and the manifold can be removed from the battery module while the first seal remains in the manifold, and the inlet includes an inner surface having a step feature formed during injection molding, a first section of the second seal having an outer diameter that contacts the inlet step feature and prevents the second seal from being removed from the inlet and away from the first portion, and the manifold can be removed from the battery module while the second seal remains in the manifold.

[0020] In yet another embodiment, a battery module is provided. The battery module includes a battery tray, a plurality of battery cells supported on the battery tray, a plurality of temperature regulating components, and a cooling assembly, each temperature regulating component having a flow path, the flow path having a feed port and a return port to receive and discharge a coolant. The cooling assembly includes a manifold, the manifold can be attached to the battery module, for supplying coolant to the temperature regulating components in the battery module and removing coolant from the temperature regulating components in the battery module, and the cooling assembly has a manifold first portion connected to the second portion of the manifold, respectively, and forms an internal supply channel and an internal removal channel. The first portion of the manifold has a supply port and a removal port, the supply port introduces the coolant into the internal supply channel, and the removal port guides the coolant out of the internal removal channel. The second portion of the manifold has an outlet and an inlet, the outlet introduces the coolant from the internal supply channel into the feed port, and the inlet introduces the coolant from the return port into the internal removal channel. A first seal is disposed in the outlet, the first seal having a first section that seals the outlet and a second section that can seal the feed port. A second seal is disposed in the inlet, the second seal having a first section that seals the inlet and a second section that is sealable to the return port.

[0021] In another aspect, a coolant supply line has a supply attachment bracket that supplies coolant to the manifold, and a coolant return line has a return attachment bracket that removes coolant from the manifold. The manifold first portion has a removable fastener engagement opening adjacent the supply port, and has a removable fastener engagement opening adjacent the removal port. The coolant supply line is attached to the supply port by the supply attachment bracket, which is attached to the manifold by a fastener in the fastener engagement opening adjacent the supply port, and the coolant return line is attached to the removal port by the return attachment bracket, which is attached to the manifold by a fastener in the fastener engagement opening adjacent the removal port.

[0022] In another aspect, the first manifold portion and the second manifold portion are separately injection molded and include a coupling element that connects the first manifold portion to the second manifold portion and forms a seal that retains coolant in the internal supply passage and the internal removal passage, the first seal being disposed in the outlet before or after the first manifold portion and the second manifold portion are connected together, and the second seal being disposed in the inlet before or after the first manifold portion and the second manifold portion are connected together.

[0023] On the other hand, the first portion of the manifold includes a rear stopper molded in the injection molding, the rear stopper is aligned with the outlet and the inlet of the second portion of the manifold, wherein the rear stopper limits the movement of the first seal in the outlet toward the first portion and limits the movement of the second seal in the inlet toward the first portion, the outlet includes an inner surface, the outlet inner surface has a step feature molded in the injection molding, the first section of the first seal has an outer diameter, the outer diameter contacts the outlet step feature and prevents the first seal from being removed from the outlet away from the first portion, and the manifold can be removed from the battery module with the first seal retained in the manifold, the inlet includes an inner surface, the inlet inner surface has a step feature formed in the injection molding, the first section of the second seal has an outer diameter, the outer diameter contacts the inlet step feature and prevents the second seal from being removed from the inlet away from the first portion, and the manifold can be removed from the battery module with the second seal retained in the manifold. Further areas of application will become apparent from the description provided herein. These descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0025] Figure 1 is a schematic diagram of an exemplary motor vehicle having a rechargeable energy storage system having a plurality of battery modules and a cooling assembly according to the principles of the present disclosure;

[0026] Figure 2 is an isometric perspective view of a battery module with a cooling assembly;

[0027] Figure 3 is an isometric view of the temperature regulation components and batteries of the battery module;

[0028] Figure 4 is an isometric perspective view of a dual function manifold according to the principles of the present disclosure;

[0029] Figure 5A is an isometric perspective view of a first portion of a dual function manifold according to the principles of the present disclosure;

[0030] Figure 5B is an isometric perspective view of a second portion of a dual function manifold according to the principles of the present disclosure;

[0031] Figure 5C is an isometric view of a first portion and a second portion of a dual function manifold being attached in accordance with the principles of the present disclosure;

[0032] Fig. 6A is an isometric perspective view of a first portion of a single-function manifold according to the principles of the present disclosure;

[0033] Figure 6B is an isometric perspective view of a second portion of a single function manifold according to the principles of the present disclosure;

[0034] Figure 6C is an isometric view of a first portion and a second portion of a single-function manifold being attached in accordance with the principles of the present disclosure;

[0035] Figure 7 is an isometric view of the seal;

[0036] Figure 8 is along Figure 4 A cross-sectional view of the dual-function manifold viewed in the direction of arrow 8-8;

[0037] Fig. 9 is along Figure 6C A cross-sectional view of the molded single-function manifold observed in the direction of arrow 9-9;

[0038] Fig.10 is along Figure 2 A cross-sectional view of a dual-function manifold attached to a battery module as viewed in the direction of arrow 10 - 10 .

[0039] Fig.11 is along Figure 2 A cross-sectional view of a single-function manifold attached to a battery module viewed in the direction of arrows 11-11;

[0040] Fig.12is an isometric perspective view of a compression limiter; and

[0041] Fig.13 is an isometric view of the attachment portion of the manifold. DETAILED DESCRIPTION

[0042] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0043] refer to Figure 1 , a rechargeable energy storage system 18 having a cooling assembly 20 and a battery module 22 according to the principles of the present disclosure is shown. As will be described in more detail below, the cooling assembly 20 is configured to cool the battery module 22. The rechargeable energy storage system 18 is shown together with a vehicle 24. The vehicle 24 shown is exemplary. Preferably, the vehicle 24 is an electric vehicle or a hybrid vehicle having wheels 26 driven by a motor / inverter 28. The motor / inverter 28 receives power from the battery module 22. Although the vehicle 24 is described as a passenger car, it should be understood that the cooling assembly 20 and the battery module 22 can be used with various other types of vehicles. For example, the cooling assembly 20 and the battery module 22 can be used in a marine vehicle such as a ship or an aerospace vehicle such as a drone or a passenger aircraft. In addition, the cooling assembly 20 and the battery module 22 can be used as a stationary power source that is separate and independent from the vehicle.

[0044] The rechargeable energy storage system 18 generally includes a battery tray 30 connected to the vehicle 24. The battery tray 30 provides structural support for one or more battery cells 32 (only one of which is shown) disposed within the battery module 22. The battery cells 32 can be cylindrical lithium-ion battery cells, as shown. However, it should be understood that any type of battery cell 32 can be used as long as the battery cell 32 is compatible with the cooling assembly 20.

[0045] Reference Figure 2 and Figure 3, the cooling assembly 20 is described with respect to two exemplary versions of the battery module 22. The cooling assembly 20 is configured to circulate a coolant 34 therein so as to cool the battery cells 32 in the battery module 22 by heat transfer. The cooling assembly 20 forms part of a larger battery thermal management system 36, which typically includes a pump 38, a heat exchanger 40, and a recovery tank 42. Without departing from the scope of the present disclosure, the battery thermal management system 36 may include various other components, including temperature and humidity sensors, heating, ventilation and air conditioning (HVAC) components, valves, and electronic controllers. Typically, the pump 38 is in fluid communication with the recovery tank 42 and pumps the coolant 34 from the recovery tank 42 to the coolant supply line 44 of the cooling assembly 20. The cooling assembly 20 directs the coolant 34 into the battery module 22 so as to cool the battery cells 32. The coolant 34 is then returned from the cooling assembly 20 through the coolant return line 46 and is transferred to the heat exchanger 40. The heat exchanger 40 removes heat from the coolant 34 , for example using a liquid-to-air heat exchanger with a fan, although other types of heat exchangers may be used. The coolant 34 returns to a recovery tank 42 .

[0046] The cooling assembly 20 includes one or more removable manifolds 48 connected to the temperature regulating components 50 in the battery module 22. The removable manifolds 48 supply coolant 34 to the coolant flow paths in the temperature regulating components 50 and remove coolant 34 from the coolant flow paths in the temperature regulating components 50 to regulate the temperature of the battery cells 32 in the battery module 22. The temperature regulating components 50 can take various forms based on the shape or type of the battery cells 32 in the battery module 22. For example, Figure 3As shown, the temperature regulating component 50 can be a strip that accommodates the cylindrical battery cells 32. Other shapes of the temperature regulating component 50 include a relatively flat surface to adapt to the flat surface battery cells, and can be referred to as a cooling plate. The temperature regulating component 50 has a feed port 52 and a return port 54 to supply coolant 34 to the internal coolant flow path and remove coolant 34 from the internal coolant flow path. The feed port 52 is generally located below the return port 54 so that the coolant 34 flowing through the internal coolant flow path enters at a low level and leaves at a high level. The manifold 48 can take a variety of functional forms to engage with the temperature regulating component 50 in the battery module 22. For example, the manifold 48 can be a dual-function manifold 56 that supplies coolant 34 to and removes coolant 34 from the temperature regulating component 50, or the manifold 48 can be a single-function manifold 58, which is a supply manifold 57 that supplies coolant 34 to the temperature regulating component 50 or a removal manifold 59 that removes coolant 34 from the temperature regulating component 50. As described in detail below, each manifold 48 has a plurality of separately molded parts connected together, the single-function manifold 58 has a single internal flow channel to support a single coolant flow function, and the dual-function manifold 56 has two internal flow channels to support two coolant flow functions. These parts are formed separately by injection molding and can be made of various materials, such as polyamide, polypropylene, and glass-reinforced PA66+GF30. Various other materials can be used and selected to provide the desired functions and capabilities.

[0047] refer to Figure 2 , Figure 4 , Figure 5A , Figure 5B , Figure 5C and Figure 8, the dual-function manifold 56 includes a first portion 60 and a second portion 62. Each portion 60, 62 is formed separately by injection molding and can be formed of various materials as described above, and then connected together to form the dual-function manifold 56. The first portion 60 includes a first cavity 61 and a second cavity 63, which, when connected with the second portion 62, form an internal supply flow channel 64 and an internal removal flow channel 66, respectively. The first portion 60 includes a supply port 68, the supply port 68 is used to receive the coolant 34 from the coolant supply line 44 and introduce the received coolant 34 into the internal supply flow channel 64; a removal port 70, the removal port 70 is used to receive the coolant 34 from the internal removal flow channel 66 and introduce the received coolant 34 into the coolant return line 46; and a removable fastener engagement feature 72 adjacent to the supply port 68 and the removal port 70 to receive a removable fastener, such as a bolt, to attach the corresponding coolant supply line 44 and the coolant return line 46. The removable fastener engagement feature 72 may be an opening and may include a threaded insert overmolded in the first portion 60. The first portion 60 has an inner surface 73 facing the second portion 62 and includes a first rib 74 extending along the perimeter, a second rib 76 extending within the first rib 74 adjacent the perimeter and between the cavities 61 and 63, a third rib 78 surrounding the first cavity 61 within the second rib 76, and a fourth rib 80 surrounding the second cavity 63 within the second rib 76. As described below, the third rib 78 and the fourth rib 80 serve as a back stop for the seal 120.

[0048] The second portion 62 includes an inlet 82 that directs the coolant 34 received from the return port 54 of the temperature adjustment component 50 into the internal removal flow passage 66, and an outlet 84 that directs the coolant 34 from the internal supply flow passage 64 into the feed port 52 of the temperature adjustment component 50. Fig.12 and Fig.13 , the second portion 62 includes an attachment section 86 having a fastener hole 88. The battery module 22 has a fastener engagement feature 89. The fastener engagement feature 89 can be a threaded opening. A removable fastener 87, such as a bolt, can attach the dual function manifold 56 to the battery module 22 via the fastener engagement feature 89. The fastener hole 88 can include a compression limiter 90, through which the removable fastener 87 is inserted. When attached to the battery module 22, the compression limiter 90 limits the compression applied to the attachment section 86. The compression limiter 90 can be overmolded in the attachment section 86, or cold or hot pressed through the fastener hole 88. The attachment section 86 can have an alignment hole 92 to accommodate the insertion of an alignment pin 94 on the battery module 22, such as Figure 3As shown, the dual function manifold 56 is aligned with the battery module 22. Alignment can be achieved by engaging at least two alignment pins 94. The second portion 62 has an inner surface 95 facing the inner surface 73 of the first portion 60 and includes a rib 96 extending along the periphery adjacent to and between the inlet 82 and the outlet 84.

[0049] refer to Figure 2 , Fig. 6A , Figure 6B , Figure 6C and Fig. 9 , the single-function manifold 58 includes a first portion 98 and a second portion 100. Each portion 98, 100 is formed separately by injection molding and can be formed of various materials as described above and then connected together to form the single-function manifold 58. The first portion 98 includes a cavity 101, which forms an internal flow passage 102 when connected with the second portion 100. The internal flow passage 102 is used to receive coolant 34 from the coolant supply line 44 when it is part of the supply manifold 57, or to return coolant 34 to the coolant return line 46 when it is part of the removal manifold 59. The first portion 98 includes a passage feature 104 that provides a passage to the internal flow passage 102 and a removable fastener engagement feature 72 adjacent to the passage feature 104 to receive a removable fastener, such as a bolt, to attach the coolant supply line 44 when it is part of the supply manifold 57, or to attach the coolant return line 46 when it is part of the removal manifold 59. When part of the supply manifold 57, the passage feature 104 will be used as a supply port for receiving coolant 34 from the coolant supply line 44 and directing the received coolant 34 into the internal flow passage 102, or when part of the removal manifold 59, the passage feature 104 will be used as a removal port for returning the coolant 34 from the internal flow passage 102 to the coolant return line 46. The removable fastener engagement feature 72 can be an opening and can include a threaded insert overmolded in the first portion 98. The first portion 98 has an inner surface 106 that faces the second portion 100 and includes a first rib 108 extending along the perimeter, a second rib 110 extending adjacent the perimeter inside the first rib 108, and a third rib 112 surrounding the cavity 101 inside the second rib 110. As described below, the third rib 112 acts as a backstop for the seal 120.

[0050] The second portion 100 includes an engagement opening 114 that provides a coolant flow path between the internal flow channel 102 in the battery module 22 and the temperature regulating component 50. The engagement opening 114 serves as an inlet that engages with the return port 54 on the temperature regulating component 50 when it is part of the removal manifold 59 to direct the received coolant 34 from the return port 54 into the internal flow channel 102, or serves as an outlet that engages with the feed port 52 on the temperature regulating component 50 when it is part of the supply manifold 57 to direct the coolant 34 from the internal flow channel 102 to the feed port 52. The second portion 100 includes an attachment section 86 having a fastener hole 88 for receiving a removable fastener, such as a bolt, to attach the single-function manifold 58 to the battery module 22 through a removable fastener engagement feature 89 on the battery module 22, such as a threaded receiving opening. The fastener hole 88 may include a compression limiter 90 through which the removable fastener may extend, which limits the compression applied to the attachment section 86 when attached to the battery module 22. The compression limiter 90 may be overmolded into the attachment section 86 and the fastener hole 88, or cold or hot pressed through the associated fastener hole 88. The attachment section 86 may have an alignment hole 92 to receive the insertion of an alignment pin 94 on the battery module 22, such as Figure 3 As shown, the single function manifold 58 is aligned with the battery module 22. Alignment can be achieved by engaging at least two alignment pins 94. The second portion 100 has an inner surface 116 facing the inner surface 106 of the first portion 98 and includes a rib 118 extending along the periphery adjacent the engagement opening 114.

[0051] refer to Figure 5C , Figure 6C , Figure 8 and Fig. 9, the dual-function manifold 56 is formed by connecting the first part 60 and the second part 62 together, and the single-function manifold 58 is formed by connecting the first part 98 and the second part 100 together. The first part 60 and the second part 62 and the first part 98 and the second part 100 are aligned with each other and can be connected together in various ways. As described below, the ribs on these parts engage with each other to form the manifold 48. In the dual-function manifold 56, the second rib 76 on the first part 60 is aligned with the rib 96 on the second part 62. In the single-function manifold 58, the second rib 110 on the first part 98 is aligned with the rib 118 on the second part 100. The aligned ribs 76, 96 and 110, 118 can be connected together by friction welding, ultrasonic welding, laser welding and adhesives. Other connection processes can also be used. The connected ribs 76, 96 connect the first part 60 and the second part 62 of the dual-function manifold 56, and form a seal around the internal supply flow channel 64 and the internal removal flow channel 66 to keep the coolant 34 within the seal. The connected ribs 110, 118 connect the first portion 98 and the second portion 100 of the single function manifold 58 and form a seal around the internal flow passage 102 to retain the coolant 34 within the seal. Seals (not shown) may also be placed between the first and second portions 60, 62 and the first and second portions 98, 100 to provide additional sealing.

[0052] refer to Figure 7 , Figure 8 , Fig. 9 , Fig.10 and Fig.11 , the manifold 48 includes a seal 120, which is integrated into the inlet 82 and outlet 84 of the second portion 62 of the dual-function manifold 56, and integrated into the joint opening 114 of the second portion 100 of the single-function manifold 58. The seal 120 has an outer section and an inner section, wherein the outer section seals the inlet 82, outlet 84 and joint opening 114, and the inner section can seal the feed port 52 and the return port 54. Fig. 9As shown in the example of FIG. 1 , each inlet 82, outlet 84, and joint opening 114 has a generally cylindrical inner surface having a first section 122 and a second section 126, the first section having a first inner diameter 124, and the second section having a second inner diameter 128 larger than the first inner diameter 124. The second section 126 is adjacent to the first portion. The larger second inner diameter 128 forms a counterbore having a step feature 130 between the first section 122 and the second section 126. The seal 120 is made of a flexible material, such as ethylene propylene diene monomer (EDPM) rubber, to seal the feed port 52 and the return port 54 of the associated manifold 48 and the associated temperature regulating component 50. The seal 120 has opposing first and second ends 133, 135 and a generally cylindrical exterior with a first section 132 and a second section 136, the first section 132 being adjacent the first end 133 and having a first outer diameter 134, and the second section 136 being adjacent the second end 135 and having a second outer diameter 138 that is greater than the first outer diameter 134. The different outer diameters 134, 138 form a ridge 140 on the seal 120 between the first section 132 and the second section 136. The size of the second outer diameter 138 can vary along the second section 136, with the largest portion adjacent the ridge 140 and the smallest portion adjacent the second end 135. The seal 120 has a generally cylindrical interior extending from the second end 135 to the first end 133 and a flexible inner circular sealing wall 142 extending from the first end 133 to the second end 135 and having an end ridge 144 therein. The inner diameter of the sealing wall 142 decreases in size as it extends from the first end 133 to the end ridge 144, and the inner diameter of the end ridge 144 is smaller than the outer diameter of the feed port 52 and the return port 54 of the temperature regulating component 50. The sealing wall 142 engages with and seals the feed port 52 or the return port 54 of the inserted temperature regulating component 50, and the feed port 52 or the return port 54 passes through and seals the end ridge 144. The seal 120 may have an internal rigid bushing to limit compression of the seal 120.

[0053] The seal 120 may be integrated into the associated manifold 48 before or after engaging the associated first and second portions 60, 62 and 98, 100 of the respective dual function manifold 56 and single function manifold 58 by inserting the seal 120 into the inlet 82 and outlet 84 of the second portion 62 of the dual function manifold 56 and into the engagement opening 114 of the second portion 100 of the single function manifold 58. The third rib 78 and the fourth rib 80 of the first portion 60 of the dual function manifold 58 are aligned with the respective inlet 82 and outlet 84 of the second portion 62 of the dual function manifold 56. The third rib 78 and the fourth rib 80 form a rear stop that may engage the second end 135 of the seal 120 and limit movement of the seal 120 within the associated inlet 82 and outlet 84 toward the first portion 60 of the dual function manifold 56. The third rib 112 of the first portion 98 of the single function manifold 58 is aligned with the engagement opening 114 of the second portion 100 of the single function manifold 58, and the third rib 112 forms a rear stop that can engage with the second end 135 of the seal 120 and limit movement of the seal 120 within the engagement opening 114 toward the first portion 98 of the single function manifold 58. As described below, the step feature 130 is a retention feature because it retains the seal 120 within the manifold 48, 56, 57, 58, 59. The step feature 130 engages with the ridge 140 of the seal 120 and prevents the seal 120 from being removed from the outlet 84 and the inlet 82 and out of the first portion 60 of the dual function manifold 56, and enables the dual function manifold 56 to be removed from the associated battery module 22 with the seal 120 retained in the dual function manifold 56. The step feature 130 engages with the ridge 140 of the seal 120 and prevents the seal 120 from being removed from the engagement opening 114 and away from the first portion 98 of the single function manifold 58 , and enables the single function manifold 58 to be removed from the associated battery module 22 while the seal 120 remains in the single function manifold 58 .

[0054] refer to Figure 2 , the coolant supply line 44 and the coolant return line 46 have attachment brackets 148 that enable the coolant supply line 44 and the coolant return line 46 to be removably attached to the manifold 48. The attachment brackets 148 include fastening features, such as bolts or openings that can receive removable fasteners, that align with the passage features 104 on the manifold 48 when the coolant supply line 44 and the coolant return line 46 are attached to the manifold 48. Connection through the attachment brackets 148 rather than the commonly used Society of Automotive Engineers (SAE) J2044 quick connectors reduces packaging space and increases ruggedness.

[0055] Forming the manifold 48 using multiple parts that are separately injection molded as described above easily incorporates complex geometries and the above-mentioned features and functions that cannot be produced by a single injection molded body. The manifold 48 can be removed from the battery module 22 and retain the seal 120, so that the rechargeable energy storage system 18 can be repaired and the seal leakage problem can be solved by replacing the relevant manifold 48 without stopping the use of the relevant battery module 22. Integrating the seal 120 in the manifold 48 rather than in the temperature regulating component 50 simplifies the design of the regulating component 50 and does not require the manufacture of a repairable regulating component 50 to repair a leaking seal 120.

[0056] 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 be 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 system manifold for a battery module, the battery module having at least one battery cell and at least one temperature regulating component, the at least one temperature regulating component having a flow path, the flow path having a feed port for receiving a coolant and a return port for discharging the coolant, the cooling system manifold comprising: a supply manifold attachable to the battery module for supplying a coolant to the at least one temperature regulating component in the battery module, the supply manifold having a supply manifold first portion connected to a supply manifold second portion respectively formed to form an internal supply channel, the supply manifold first portion having a supply port for introducing a coolant into the internal supply channel, the supply manifold second portion having an outlet for introducing a coolant from the internal supply channel to the feed port; A first sealing member disposed in the outlet, the first sealing member having a first section that seals the outlet and a second section that can seal the feed port; a removal manifold attachable to the battery module for removing coolant from the at least one temperature regulating component in the battery module, the removal manifold having a removal manifold first portion respectively formed to connect to a removal manifold second portion to form an internal removal channel, the removal manifold first portion having a removal port for directing coolant out of the internal removal channel, the removal manifold second portion having an inlet for directing coolant from the return port into the internal removal channel; as well as A second sealing member is disposed in the inlet, wherein the second sealing member has a first section that seals the inlet and a second section that can seal the return port.

2. The cooling system manifold according to claim 1, wherein: The supply manifold second portion has a plurality of attachment sections, and the supply manifold second portion attachment sections are attached to the battery module via removable fasteners, and the removal manifold second portion has a plurality of attachment sections, and the removal manifold second portion attachment sections are attached to the battery module via removable fasteners.

3. The cooling system manifold of claim 2, further comprising compression limiters disposed in the supply manifold second portion attachment section and the removal manifold second portion attachment section, wherein: The compression limiter limits compression of the supply manifold attachment section by the removable fasteners attaching the supply manifold to the battery module and limits compression of the removal manifold attachment section by the removable fasteners attaching the removal manifold to the battery module.

4. The cooling system manifold according to claim 2, wherein: The second part attachment section of the supply manifold has two alignment holes, which accept the insertion of the alignment pins on the battery module and align the supply manifold with the battery module. The second part attachment section of the removal manifold has two alignment holes, which accept the insertion of the alignment pins on the battery module and align the removal manifold with the battery module.

5. The cooling system manifold according to claim 1, wherein: A coolant supply line having a supply attachment bracket supplies coolant to the supply manifold, a coolant return line having a return attachment bracket removes coolant from the removal manifold, the supply manifold first portion having a removable fastener engagement opening adjacent to the supply port, the removal manifold first portion having a removable fastener engagement opening adjacent to the removal port, the coolant supply line being attached to the supply port via the supply attachment bracket, the supply attachment bracket being attached to the supply manifold via a fastener in the supply manifold fastener engagement opening, the coolant return line being attached to the removal port via the return attachment bracket, the return attachment bracket being attached to the removal manifold via a fastener in the removable manifold fastener engagement opening.

6. The cooling system manifold according to claim 1, wherein: The first supply manifold portion and the second supply manifold portion are injection molded separately and include a coupling element, which connects the first supply manifold portion to the second supply manifold portion and forms a seal to retain coolant in the internal supply channel, and the first seal is disposed in the outlet before or after the first supply manifold portion and the second supply manifold portion are connected together. The first removal manifold portion and the second removal manifold portion are injection molded separately and include a coupling element, which connects the first removal manifold portion to the second removal manifold portion and forms a seal to retain coolant in the internal removal channel, and the second seal is disposed in the inlet before or after the first removal manifold portion and the second removal manifold portion are connected together.

7. The cooling system manifold according to claim 6, wherein: The first supply manifold portion includes a rear stop formed in the injection molding and aligned with the outlet, wherein the supply manifold rear stop limits the first seal from moving in the outlet toward the first supply manifold portion, and the first removal manifold portion includes a rear stop formed in the injection molding and aligned with the inlet, wherein the removable manifold rear stop limits the second seal from moving in the inlet toward the first removal manifold portion.

8. The cooling system manifold according to claim 6, wherein: The outlet includes an inner surface having a step feature formed in the injection molding, a first section of the first seal having an outer diameter that contacts the outlet step feature and prevents the first seal from being removed from the outlet away from the first portion of the supply manifold, and enables the supply manifold to be removed from the battery module while the first seal remains in the supply manifold, and the inlet includes an inner surface having a step feature formed in the injection molding, a first section of the second seal having an outer diameter that contacts the inlet step feature and prevents the second seal from being removed from the inlet away from the first portion of the removal manifold, and enables the removable manifold to be removed from the battery module while the second seal remains in the removable manifold.

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