Cooling jacket for prismatic battery of rechargeable energy storage system

Abstract

A prismatic battery cooling system includes a first prismatic battery having a first face, a second face angularly oriented to the first face, and a third face oriented parallel to the first face and angularly oriented to the second face. The cooling jacket provides a plurality of coolant flow channels. The first cooling section of the cooling jacket contacts one of the first face or the third face of the first prismatic cell. The second cooling section of the cooling jacket is in direct contact with the second face of the first prismatic cell. The second cooling section is continuous and fluidly connected to the first cooling section to facilitate simultaneous cooling of one of the first face or the third face and the second face of the first prismatic cell by a coolant flowing through the coolant flow channel.

Description

Technical Field

[0001] The present disclosure relates to a cooling system and a cooling jacket for an automotive energy storage system. Background Art

[0002] When battery-powered vehicles (such as sports cars and vehicles) are used for rapid acceleration, heavy load carrying and towing, some vehicle prismatic battery designs require increased cooling of the prismatic battery. Cooling systems for vehicle prismatic batteries typically use only a single cooling plate that contacts a single side of the prismatic battery to provide cooling of the prismatic battery. The single-sided cooling concept may not be suitable for vehicle prismatic battery designs that require enhanced prismatic battery cooling.

[0003] Therefore, while current systems and methods for cooling vehicle prismatic batteries achieve their intended purposes, a new and improved system and method is needed for cooling prismatic batteries for electric and hybrid vehicles. Summary of the invention

[0004] According to several aspects, a prismatic battery cooling system includes a first prismatic battery having a first face, a second face oriented at an angle to the first face, and a third face oriented parallel to the first face and oriented at an angle to the second face. A cooling jacket provides a plurality of coolant flow channels. A first cooling section of the cooling jacket contacts one of the first face or the third face of the first prismatic battery. A second cooling section of the cooling jacket directly contacts the second face of the first prismatic battery. The second cooling section is continuously and fluidly connected to the first cooling section to facilitate simultaneous cooling of one of the first face or the third face and the second face of the first prismatic battery by flowing coolant through the coolant flow channels.

[0005] In another aspect of the present disclosure, the cooling jacket defines a second prismatic battery having a first battery face, a second battery face oriented angularly to the first battery face, and a third battery face oriented parallel to the first battery face and angularly to the second battery face, the second prismatic battery being located adjacent to the first prismatic battery.

[0006] In another aspect of the present disclosure, the cooling jacket defines a T-shape having a first cooling segment located between and directly contacting the first prismatic battery and the second prismatic battery. The cooling jacket has a second cooling segment directly contacting the second face of the first prismatic battery and the second face of the battery of the second prismatic battery.

[0007] In another aspect of the present disclosure, the cooling jacket defines an L-shape having a first cooling segment located between and directly contacting the first prismatic battery and the second prismatic battery. The cooling jacket has a second cooling segment directly contacting one of the second face of the first prismatic battery or the second face of the battery of the second prismatic battery.

[0008] In another aspect of the present disclosure, the cooling jacket defines a Z-shape having a first cooling segment located between and directly contacting a first prismatic battery and a second prismatic battery. The cooling jacket has a second cooling segment directly contacting a second face of the first prismatic battery, and the cooling jacket includes a third cooling segment directly contacting a fourth face of the battery of the second prismatic battery.

[0009] In another aspect of the present disclosure, the cooling jacket defines a U-shape having a first cooling section located between and directly contacting the first prismatic battery and the second prismatic battery, and the cooling jacket having a second cooling section directly contacting the second face of the first prismatic battery or one of the second faces of the battery of the second prismatic battery.

[0010] In another aspect of the present disclosure, a third prismatic battery is provided, wherein: the first cooling segment partially surrounds the first prismatic battery; the second cooling segment partially surrounds the second prismatic battery; and the third cooling segment of the cooling jacket partially surrounds the third prismatic battery.

[0011] In another aspect of the disclosure, a first thermal insulation barrier is located between and in direct contact with the first cooling segment and the second cooling segment. A second thermal insulation barrier is located between and in direct contact with the second cooling segment and the third cooling segment.

[0012] In another aspect of the present disclosure, the cooling jacket includes a plurality of flow turbulators extending into the coolant flow channel to generate turbulent flow of the coolant, with individual flow turbulators defining one of a serpentine shape and a lug.

[0013] In another aspect of the present disclosure, the second face is oriented substantially perpendicular to the first face, and the third face is oriented parallel to the first face and substantially perpendicular to the second face.

[0014] According to various aspects, a vehicle prismatic battery cooling system includes at least a first prismatic battery and a second prismatic battery, each having a first face, a second face oriented at an angle to the first face, and a third face oriented parallel to the first face and oriented at an angle to the second face. A first cooling jacket provides a plurality of coolant flow channels, and the first cooling jacket is in direct contact with the first prismatic battery. A first cooling section of the first cooling jacket contacts one of the first face or the third face of the first prismatic battery. A second cooling section of the first cooling jacket directly contacts the second face of the first prismatic battery. The second cooling section is continuously and fluidly connected to the first cooling section to facilitate simultaneous cooling of at least one of the first face or the third face and the second face of the first prismatic battery by flowing coolant through the coolant flow channels.

[0015] In another aspect of the present disclosure, a second cooling jacket is included, the first cooling jacket is in direct contact with the first prismatic battery cell, and the second cooling jacket is in direct contact with the second prismatic battery cell.

[0016] In another aspect of the present disclosure, a third prismatic battery having at least a first prismatic battery and a second prismatic battery is provided; a third cooling jacket is also provided, the first cooling jacket is in direct contact with the first prismatic battery, the second cooling jacket is in direct contact with the second prismatic battery, and the third cooling jacket is in direct contact with the third prismatic battery.

[0017] In another aspect of the present disclosure, the first cooling jacket is also in direct contact with the second prismatic battery cell; and the second cooling jacket is in direct contact with the third prismatic battery cell.

[0018] In another aspect of the present disclosure, a second cooling jacket is provided; wherein the first cooling jacket is in direct contact with the first prismatic battery cell, and the second cooling jacket is in direct contact with the second prismatic battery cell.

[0019] In another aspect of the present disclosure, the thermal insulation barrier is located between and in direct contact with the first cooling jacket and the second cooling jacket.

[0020] In another aspect of the present disclosure, the material for the first cooling jacket includes one of: aluminum, copper, and steel; and the first cooling jacket includes a plurality of turbulence features formed in at least one of the first cooling section and the second cooling section to increase flow turbulence of the coolant.

[0021] According to several aspects, a method for cooling a vehicle prismatic battery using a cooling jacket includes: configuring at least a first prismatic battery and a second prismatic battery, each having a first face, a second face oriented at an angle to the first face, and a third face oriented parallel to the first face and oriented at an angle to the second face; positioning the first cooling jacket in direct contact with at least one of the first prismatic battery or the second prismatic battery, and providing a plurality of coolant flow channels within the first cooling jacket; placing a first cooling section of the first cooling jacket having a plurality of coolant flow channels among the plurality of coolant flow channels in contact with one of the first face or the third face of at least one of the first prismatic battery or the second prismatic battery; positioning a second cooling section of the first cooling jacket having a plurality of coolant flow channels among the plurality of coolant flow channels in direct contact with a second face of at least one of the first prismatic battery or the second prismatic battery, the second cooling section being continuously and fluidly connected to the first cooling section to cool the first face or the third face and one of the second face of at least one of the first prismatic battery or the second prismatic battery while passing a coolant through the coolant flow channels.

[0022] In another aspect of the present disclosure, the method further includes: selecting the first cooling jacket to be in direct contact with the first prismatic battery cell; and positioning the second cooling jacket to be in direct contact with the second prismatic battery cell.

[0023] In another aspect of the present disclosure, the method further includes thermally isolating the first cooling jacket from the second cooling jacket by positioning a first thermal insulation barrier between and in direct contact with the first cooling jacket and the second cooling jacket.

[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 an end elevation view of a prismatic battery according to an exemplary aspect;

[0027] Figure 2 is configured in the first cooling system of the prismatic battery cooling jacket and manifold system of the present disclosure Figure 1 An end elevation view of a first prismatic battery and a second prismatic battery;

[0028] Figure 3 yes Figure 2 a top perspective view of a cooling jacket as viewed from the rear;

[0029] Figure 4 is similar to Figure 1 An end elevation view of a prismatic battery;

[0030] Figure 5 is an end elevation view of an L-shaped cooling system for three prismatic batteries of the present disclosure;

[0031] Figure 6 is an end elevation view of a U-shaped cooling system for three prismatic batteries of the present disclosure;

[0032] Figure 7 is a top view of a cooled quadrilateral prismatic battery according to an exemplary aspect;

[0033] Figure 8 is an end elevation view of a three prismatic battery Z-shaped cooling system of the present disclosure;

[0034] Fig. 9 yes Figure 8 A side perspective view of a Z-shaped cooling jacket from the rear;

[0035] Fig.10 yes Figure 5 A front perspective view of the L-shaped cooling system for three prismatic cells, also showing the coolant flow channels; and

[0036] Fig.11 yes Figure 6 A front perspective view of the L-shaped cooling system for the three prismatic batteries, also showing the coolant flow channels. DETAILED DESCRIPTION

[0037] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0038] When a component, element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged to, connected to, or coupled to another element or layer, or there may be intermediate elements or intermediate layers. Conversely, when an element is referred to as being "on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intermediate elements or intermediate layers. Other words used to describe the relationship between elements should be interpreted in a similar manner, such as "between" versus "directly between," "adjacent" versus "directly adjacent," "close to" versus "directly close to," etc. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0039] As used herein, various cooling jacket systems have a cooling jacket or coolant jacket, respectively, and the cooling jacket or coolant jacket includes a plurality of sections, and the plurality of sections have names defining sides, faces, walls, main body members, legs, etc., for distinguishing different sections from the plurality of sections. As used herein, a prismatic battery defines a battery cell or rechargeable energy storage cell having a square or rectangular shape including a plurality of generally flat sides. The plurality of sections respectively include a plurality of coolant channels, flow channels, etc., providing a flow of coolant to remove heat from the prismatic battery of the present disclosure.

[0040] refer to Figure 1 , the prismatic battery cooling system 10 can be used in a vehicle 11, such as a car, a truck, a van, a sport utility vehicle, a sports car, a tractor, an autonomous vehicle, a battery electric vehicle, etc. The prismatic battery cooling system 10 cools at least one prismatic battery 12, and according to several aspects, multiple prismatic batteries 12 are identified below with lowercase letters such as a, b, c, etc. Multiple similar components can also be identified using an asterisk ("*"). Multiple prismatic batteries 12 can form a rechargeable energy storage system (RESS) or a battery pack 13, which is only partially shown. The prismatic battery 12 includes a first side 14 facing outward and a second bottom or second side 16 oriented generally transverse to the first side 14. The geometry of each prismatic battery can vary, and the prismatic battery 12 has a generally rectangular shape, including a width 18 and a height 20 that are repeated between each prismatic battery 12 of the battery pack 13, which is only partially shown. 13 and 14, prismatic battery terminals for extracting power or recharging the prismatic battery 12 are shown and described in more detail and are located on a top surface or third side 22 opposite the second side 16 according to several aspects. The prismatic battery 12 also includes an outer surface or fourth side 24 opposite the first side 14. The first side 14 and the fourth side 24 are generally oriented laterally relative to the second side 16 and the third side 22.

[0041] refer to Figure 2 And refer again Figure 1As described below, the first cooling jacket system 26 provides simultaneous coolant flow to up to and including two consecutive sides of the prismatic battery. According to several aspects, the first cooling jacket system 26 includes two prismatic batteries that can be cooled using a liquid cooling flow that is used to remove heat generated by the two prismatic batteries 12. According to several aspects, the cooling flow path of the first cooling jacket system 26 can be configured as a cooling jacket defining an inverted T-shaped jacket 28 of the prismatic battery cooling system 10. The inverted T-shaped jacket 28 includes an upward vertical wall 30 that is centrally located between a first prismatic battery 12a of the two prismatic batteries 12 and a second prismatic battery 12b of the two prismatic batteries 12 and directly contacts the first prismatic battery 12a of the two prismatic batteries 12 and the second prismatic battery 12b of the two prismatic batteries 12. The inverted T-shaped jacket 28 further includes a first branch wall 32 fluidly, directly and continuously connected to the upward vertical wall 30 , and a second branch wall 34 fluidly, directly and continuously connected to the upward vertical wall 30 and the first branch wall 32 .

[0042] The cooling fluid may be introduced into the cooling jacket via one or more internal flow passages of the cooling jacket (such as the internal flow passages of the first branch wall 32), referring to Figure 10 to Figure 1 4 is shown and described in more detail in the first direction A, turns upward into the upward vertical wall 30 in the second direction B, reverses in the third direction C at the upper end of the upward vertical wall 30, travels downward in the upward vertical wall 30, and leaves the first cooling jacket system 26 in the flow direction D via the inner flow channel of the second branch wall 34. Figure 1 As described, for example, the cooling fluid may be provided by a cooling system of the vehicle 11. The first cooling jacket system 26 provides simultaneous coolant flow to two consecutive sides of the prismatic battery.

[0043] refer to Figure 3 And refer again Figure 1 and Figure 2, the inverted T-shaped jacket 28 provides an internal cavity or fluid flow channel for guiding the coolant fluid. For example, the upward vertical wall 30 includes a first internal cavity 40 and a first branch wall 32, and the second branch wall 34 also includes a second internal recess 42 for internal fluid flow. The inverted T-shaped jacket 28 can also be modified using one or more flow redirecting elements discussed below to change the direction of the coolant flow as needed. According to several aspects, the coolant flow can enter the second internal recess 42 of the first branch wall 32 and the second branch wall 34 along the flow direction E until encountering the end wall 44, which redirects the coolant flow into the first internal cavity 40 of the upward vertical wall 30 along the upward direction F. Within the first internal cavity 40, the coolant flow can initially be directed along the flow direction G, which is reversed to flow in a countercurrent direction H to the flow direction G. The coolant flow can leave the first internal cavity 40 along the flow direction J.

[0044] Turbulence is maintained by maximizing the Reynolds number to optimize heat removal. Turbulence can be achieved using flow conditioners such as the first turbulator 46, the second turbulator 48 and the third turbulator 50, which respectively define raised serpentine ribs arranged on the inner-facing wall of the first internal cavity 40. Different numbers of flow turbulators can also be used. In addition to providing directional control of the coolant flow, the first turbulator 46, the second turbulator 48 and the third turbulator 50 also provide continuous coolant flow direction changes, which maximizes the turbulence of the coolant. In addition to the first turbulator 46, the second turbulator 48 and the third turbulator 50 or in place of the first turbulator 46, the second turbulator 48 and the third turbulator 50, a plurality of convex pins 53 fixedly connected to at least one inner wall of the first internal cavity 40 can be used to generate turbulence and change the coolant flow direction. After passing through the first internal cavity 40, the coolant flow can leave the first internal cavity 40 at the end wall 52. In addition to using serpentine turbulators, turbulence can also be achieved by using turbulators that define straight fins, wavy fins, pin fins, honeycomb fins, triangular fins, herringbone fins, elliptical fins, and the like.

[0045] refer to Figure 4 And refer again Figures 1 to 3 , the single prismatic battery 54 is similar to the prismatic battery 12. To further enhance prismatic battery cooling, in addition to providing simultaneous cooling of the continuously connected outward first side 14 and the bottom or second side 16, a coolant flow may be provided to the outward third side 56 opposite the first side 14 and completely and continuously connected to the second side 16. Thus, for example, reference may be made to the following Figure 5 and Figure 6 The cooling jacket design shown and described in greater detail provides cooling to the first side 14 , the second side 16 , and the third side 56 simultaneously.

[0046] refer to Figure 5 And refer again Figure 4 , the second cooling jacket system 58 is modified from the first cooling jacket system 26 and provides simultaneous coolant flow to up to and including three consecutive sides of one or more prismatic batteries as described below. According to several aspects, the second cooling jacket system 58 includes three prismatic batteries 54 that define a substantially repeating first prismatic battery 54, a second prismatic battery 54a, and a third prismatic battery 54b. The first prismatic battery 54, the second prismatic battery 54a, and the third prismatic battery 54b can be cooled using the provided liquid cooling flow to remove heat generated by the three prismatic batteries. According to several aspects, the cooling flow path of the second cooling jacket system 58 can be configured using the L-shaped jacket of the prismatic battery cooling system 10.

[0047] The second cooling jacket system 58 also includes a first L-shaped bracket 60, a second L-shaped bracket 62, and a third L-shaped bracket 64 having similar structures. The first L-shaped bracket 60 is mainly located on the left side of the first prismatic battery 54, such as Figure 5 , and includes a first body member 66, and the first body member 66 is located outside and in direct contact with the first side 14 of the first prismatic battery 54. The first base member 68 is oriented at a right angle relative to the first body member 66, and is directly and continuously connected to the first body member 66 and provides fluid flow between the first body member 66 and the first base member 68. The first side 14 of the first prismatic battery 54 is positioned in direct contact with the body member inner wall 70, and the second side 16 of the first prismatic battery 54 is positioned in direct contact with the first base member inner wall 72.

[0048] Continue to refer Figure 5 , the second body member 74 of the second L-shaped bracket 62 is primarily located between the first prismatic battery 54 and the second prismatic battery 54a. The second base member 76 is oriented at a right angle relative to the second body member 74 and is directly and continuously connected to the second body member 74 and provides fluid flow between the second body member 74 and the second base member 76. The first face 78 of the second body member 74 is in direct contact with the third side 56 of the first prismatic battery 54. The second face 80 of the second body member 74 is in direct contact with the first side 14a of the second prismatic battery 54a. The second side 16a of the second prismatic battery 54a is positioned in direct contact with the second base member inner wall 82 of the second base member 76. According to several aspects, the first base member 68 can remain in direct contact with the second base member 76, or an air gap 84 can be provided between the first base member 68 and the second base member 76.

[0049] Continue to refer Figure 5, the third main body member 86 of the third L-shaped bracket 64 is mainly located between the second prismatic battery 54a and the third prismatic battery 54b. The third base member 88 is oriented at a right angle relative to the third main body member 86 and is directly and continuously connected to the third main body member 86 and provides fluid flow between the third main body member 86 and the third base member 88. The first battery face 90 of the third main body member 86 is in direct contact with the third side 56a of the second prismatic battery 54a. The second battery face 91 of the third main body member 86 is in direct contact with the third side 56a of the second prismatic battery 54a. The second side 16b of the third prismatic battery 54b is positioned to be in direct contact with the third base member inner wall 92 of the third base member 88. According to several aspects, the third side 56b of the third prismatic battery 54b can be open to the atmosphere. According to several aspects, the second base member 76 can remain in direct contact with the third base member 88, or an air gap 94 can be provided between the second base member 76 and the third base member 88.

[0050] refer to Figure 6 , similar to the second cooling jacket system 58, the third cooling jacket system 96 provides simultaneous coolant flow to up to and including three consecutive sides or faces of one or more prismatic batteries as described below. According to several aspects, the third cooling jacket system 96 includes three prismatic batteries 54, which define a substantially repeating first prismatic battery 54, a second prismatic battery 54a, and a third prismatic battery 54b. The first prismatic battery 54, the second prismatic battery 54a, and the third prismatic battery 54b can be cooled using the provided liquid cooling flow to remove heat generated by the three prismatic batteries. According to several aspects, the cooling flow path of the third cooling jacket system 96 can be configured using the U-shaped jacket of the prismatic battery cooling system 10.

[0051] The third cooling jacket system 96 includes a first U-shaped bracket 98. The first U-shaped bracket 98 is positioned to directly contact three sides of the first prismatic battery 54, such as Figure 61 and includes a first body member 100 located outside and in direct contact with a first side 14 of a first prismatic battery 54. A first base member 102 is oriented at a right angle relative to the first body member 100 and is directly and continuously connected to the first body member 100 and provides fluid flow between the first body member 100 and the first base member 102. The first side 14 of the first prismatic battery 54 is positioned in direct contact with the first body member inner wall 104, and the second side 16 of the first prismatic battery 54 is positioned in direct contact with the first base member inner wall 106. The second body member 108 is oriented generally parallel to the first body member 100 and is oriented at a right angle relative to the first base member 102 and is directly and continuously connected to the first base member 102 and provides fluid flow between the second body member 108 and the first base member 102. The third side 56 of the first prismatic battery 54 is positioned in direct contact with the second base member inner wall 110. The first prismatic battery 54 is located between the first body member 100 and the second body member 108 and is in direct contact with the first body member 100 and the second body member 108 and also in direct contact with the first base member 102 .

[0052] Continue to refer Figure 6 , the third cooling jacket system 96 also includes a second U-shaped bracket 112 and a third U-shaped bracket 114 that partially surround the second prismatic battery 54a and the third prismatic battery 54b, respectively. The second U-shaped bracket 112 and the third U-shaped bracket 114 include components, features and functions that are the same or similar to those discussed above with respect to the first U-shaped bracket 98, and therefore will not be repeated herein. In order to mitigate the possibility of a thermal runaway event in a battery pack having prismatic batteries of the present disclosure, the third cooling jacket system 96 provides a thermal insulation barrier located between adjacent prismatic batteries. According to several aspects, the first thermal insulation barrier 116 is located between the second body member 108 and the body member 118 of the second U-shaped bracket 112, and is in direct contact with the second body member 108 and the body member 118 of the second U-shaped bracket 112. The first thermal insulation barrier 116 is in direct contact with the outward face 120 of the second body member 108, and, correspondingly, is in direct contact with the outward face 122 of the body member 118.

[0053] Continue to refer Figure 6 A second thermal insulation barrier 124 is disposed between the second U-shaped bracket 112 and the third U-shaped bracket 114. The third body member 126 of the second U-shaped bracket 112 includes an outward surface 128 directly in contact with the second thermal insulation barrier 124, and the first body member 130 of the third U-shaped bracket 114 includes an outward surface 132 directly in contact with the second thermal insulation barrier 124.

[0054] refer to Figure 7And refer again Figure 1 and Figure 4 , the four-sided prismatic battery cooling design 134 includes a single prismatic battery 136 modified from the prismatic battery 12. To further enhance prismatic battery cooling, in addition to providing simultaneous cooling of the outward first side 138, the first end or second side 140, and the outward third side 142 opposite the outward first side 138, coolant flow may also be provided to the second end or fourth side 144 opposite the second side 140. Thus, for example, using reference to the following Figure 8 and Fig. 9 The cooling jacket design shown and described in greater detail can provide cooling to the outward first side 138 , the outward second side 140 , the outward third side 142 , and the outward fourth side 144 simultaneously.

[0055] refer to Figure 8 And refer again Figure 7 , the fourth cooling jacket system 146 can provide simultaneous coolant flow to up to and including four consecutive sides or faces of the prismatic cell as described below. The fourth cooling jacket system 146 provides a Z-shaped cooling jacket, such as a first Z-shaped cooling jacket 148 and a second Z-shaped cooling jacket 150. The first Z-shaped cooling jacket 148 includes a first base leg 151 directly in contact with the second side 140 of the prismatic cell 136, a first main leg 152 directly in contact with the third side 142 of the prismatic cell 136 and opposite the first side 138a of the prismatic cell 136a, and a second base leg 154 directly in contact with the fourth side 144a of the prismatic cell 136a.

[0056] The second Z-shaped cooling jacket 150 includes a first base leg 156 abutting the first base leg 150 and in direct contact with the second side 140a of the prismatic cell 136a, a first main leg 158 in direct contact with the third side 142a of the prismatic cell 136a and opposite the first side 138b of the prismatic cell 136b, and a second main base leg 160 in direct contact with the fourth side 144b of the prismatic cell 136b. According to several aspects, the fourth cooling jacket system 146 provides direct contact with a cooling portion of one of the first Z-shaped cooling jacket 148 and the second Z-shaped cooling jacket 150 to cool four sides of the prismatic cell 136. In the example shown, the first side 138 and the fourth side 144 of the prismatic cell 136 are not directly cooled, and the second side 140b and the third side 142b of the prismatic cell 136 are not directly cooled. Thus, when a specific prismatic cell heat load is identified, the fourth cooling jacket system 146 may be selected.

[0057] refer to Fig. 9 And refer again Figure 8, a coolant flow diagram 162 presents exemplary coolant flow paths for each of the above-described Z-shaped cooling jackets. The coolant flow is longitudinal in the first base leg 150 and the first base leg 156 along the flow direction K. The first base leg 150 and the first base leg 156 are respectively continuously and fluidly connected to the first main leg 152 and the first main leg 158. The coolant flow is longitudinal in the first main leg 152 and the first main leg 158 along the flow direction L, and turbulence may be presented using one or more turbulence features 164, which are configured to include a geometric pattern within the illustrated row 166. The first main leg 152 and the first main leg 158 are respectively continuously and fluidly connected to the second base leg 154 and the second base leg 160. The coolant flow is longitudinal in the second base leg 154 and the second base leg 160 along the flow direction M.

[0058] refer to Fig.10 And refer again Figure 5 , compared with reference Figure 5 The depicted second cooling jacket system 58 shows the second cooling jacket system 58a in greater detail and presents a portion of the battery pack 168 with exemplary coolant flow channels or passages. A plurality of prismatic cells, such as the prismatic cell 54 and the prismatic cell 54', are configured in the battery arrangement 170, and the battery pack 168 may also include a plurality of additional prismatic cells that are not shown for clarity.

[0059] The individual coolant flow passages or channels may include a plurality of flow channels 172 within the first body member 66, a plurality of flow channels 174 extending through the first base member 68, a plurality of flow channels 176 extending through the second body member 74, a plurality of flow channels 178 extending through the second base member 76, a plurality of flow channels 180 extending through the third body member 86, and a plurality of flow channels 182 extending through the third base member 88. The plurality of flow channels extend generally parallel to the battery arrangement 170. The coolant flow through each of the plurality of flow channels may be the same, may alternate, or may change direction based on the prismatic battery thermal load and the desired cooling rate.

[0060] refer to Fig.11 And refer again Figure 6 , compared with reference Figure 6The third cooling jacket system 96 is depicted with the third cooling jacket system 96a being shown in greater detail. The separate coolant flow passages or channels may include a plurality of flow channels 184 within the first body member 100, a plurality of flow channels 186 extending through the first base member 102, and a plurality of flow channels 188 extending through the second body member 108. Additional and substantially identical coolant flow channels (shown) are provided for the second U-shaped bracket 112 and the third U-shaped bracket 114, but are not numbered for clarity. As described with reference to Figure 6 As shown, the first thermal insulation barrier 116 is located between and in direct contact with the second body member 108 and the body member 118 of the second U-shaped bracket 112, and the second thermal insulation barrier 124 is located between the second U-shaped bracket 112 and the third U-shaped bracket 114. The first thermal insulation barrier 116 and the second thermal insulation barrier 124 provide additional thermal isolation between the prismatic battery packs to mitigate thermal runaway in one or more prismatic batteries or prismatic battery packs.

[0061] The coolant flow can be in any direction, inward or outward, as shown in reference Fig.11 As shown, for coolant flow channels. The coolant flow can also enter one coolant flow channel and exit from an adjacent coolant flow channel in the reverse direction. This allows for optimization of heat dissipation for different prismatic cell and battery pack design requirements.

[0062] The prismatic battery form defines a heat generating source. The cooling jacket may include a design responsible for containing a heat transfer fluid and conducting heat between a heat generating source, such as a battery cell or prismatic battery, and a heat sink or cooling jacket.

[0063] Features of the prismatic battery cooling system 10 may include: 1) an integrated multi-surface cooling concept that provides a larger effective cooling area; 2) L-shaped jackets, U-shaped jackets, inverted T-shaped jackets, Z-shaped jackets, and turbulent flow features to enhance the performance of the cooling jackets regardless of multi-surface cooling advantages, such as increased Reynolds number and thermal conductivity, such as straight fins, corrugated fins, pin fins, honeycomb fins, triangular fins, herringbone fins, and elliptical fins.

[0064] Materials for the cooling jacket system of the prismatic battery cooling jacket system 10 of the present disclosure may include: aluminum, which is affordable, provides moderate thermal conductivity, and is lightweight; copper, which provides high thermal conductivity but is heavier than aluminum; and steel, which is affordable but has lower thermal conductivity and is heavier than copper.

[0065] Multi-port cooling and manifolds: The cooling jacket can facilitate the distribution of coolant flow to inlets and outlets, integration between the rechargeable energy storage system (RESS) thermal loop and the vehicle thermal loop, and coolant system sealing and containment. Thermal interface material (TIM) defines an adhesive or filler layer applied to the prismatic cell surface to match the uneven surface between prismatic cells. The cooling jacket design of the present invention facilitates the adaptation of TIM distribution to further promote thermal benefits through the thermal conductivity properties of the TIM material (including having a low heat transfer coefficient).

[0066] The prismatic battery cooling jacket system 10 of the present disclosure uses the cooling capacity of the variable length cooling jacket and the RESS space dimensions to provide integrated multi-surface thermal management of the prismatic battery. The prismatic battery cooling jacket system 10 of the present disclosure provides a modular thermal system. The prismatic battery cooling jacket system 10 of the present disclosure supports cell-to-module, cell-to-battery pack, and module-to-RESS structures.

[0067] The prismatic battery cooling jacket system 10 of the present disclosure includes multiple continuous or staggered turbulence features that can be implemented in the cooling channels, such as straight microchannels, wave turbulators, flow redirection pins, fin arrays and other fin forms. The prismatic battery cooling jacket system 10 of the present disclosure includes cooling ports, both inlet and outlet ports that can be integrated into the cooling jacket. The prismatic battery cooling jacket system 10 of the present disclosure provides a repeatable thermal management solution for prismatic batteries, including high-performance prismatic batteries, such as in vehicles, including but not limited to sports cars, tractors, etc., which may generate more heat than nominal performance vehicles during normal driving operations, and provides a rechargeable energy storage system using a multi-surface liquid cooling jacket and manifold.

[0068] The prismatic battery cooling jacket system 10 of the present disclosure has several major advantages. These advantages include, but are not limited to, improved thermal performance, reduced maximum battery internal temperature, reduced local battery temperature gradients, improved vehicle durability, adaptability to variable RESS geometries (including T-shaped, H-shaped, flat pack, suitcase packaging, etc.), reduced thermal resistance from the center plane of the prismatic battery to the heat sink, reduced costs, and improved manufacturability for large-scale production. The cooling jacket concept of the present disclosure also provides a support structure for multiple batteries to aid in manufacturing. The exemplary shapes of the cooling jackets proposed herein optimize thermal efficiency, reduce pressure drop, and achieve fluid flow uniformity, and the cooling jacket provides the ability to act as a spring clip to manage thermal interface materials (TIMs).

Claims

1. A prismatic battery cooling system comprising: a first prismatic cell having a first face, a second face oriented at an angle to the first face, and a third face oriented parallel to the first face and oriented at an angle to the second face; a cooling jacket, the cooling jacket providing a plurality of coolant flow channels; a first cooling section of the cooling jacket, the first cooling section of the cooling jacket contacting one of the first face or the third face of the first prismatic battery; and The second cooling section of the cooling jacket directly contacts the second side of the first prismatic battery, and the second cooling section is continuously and fluidically connected to the first cooling section to promote simultaneous cooling of the first side or the third side and the second side of the first prismatic battery by flowing the coolant through the coolant flow channel.

2. The prismatic battery cooling system of claim 1 , further comprising: A second prismatic battery having a first battery face, a second battery face oriented at an angle to the first battery face, and a third battery face oriented parallel to the first battery face and oriented at an angle to the second battery face, the second prismatic battery being positioned adjacent to the first prismatic battery.

3. The prismatic battery cooling system of claim 2, wherein: The cooling jacket defines a T-shape having a first cooling segment between and in direct contact with the first and second prismatic cells, and a second cooling segment also in direct contact with a second cell face of the second prismatic cell.

4. The prismatic battery cooling system of claim 2, wherein: The cooling jacket defines an L-shape having the first cooling segment between and in direct contact with the first prismatic battery and the second prismatic battery, and the cooling jacket having the second cooling segment in direct contact with one of the second face of the first prismatic battery or the second face of the second prismatic battery.

5. The prismatic battery cooling system of claim 2, wherein: The cooling jacket defines a Z-shape having the first cooling segment between and in direct contact with the first prismatic battery and the second prismatic battery, the cooling jacket having the second cooling segment also in direct contact with the second face of the first prismatic battery, and the cooling jacket including a third cooling segment in direct contact with a fourth face of the second prismatic battery.

6. The prismatic battery cooling system of claim 2, wherein: The cooling jacket defines a U-shape having a first cooling section located between the first prismatic battery and the second prismatic battery and in direct contact with the first prismatic battery and the second prismatic battery, and the cooling jacket has a second cooling section in direct contact with the second face of the first prismatic battery or one of the second faces of the battery of the second prismatic battery.

7. The prismatic battery cooling system of claim 2, comprising: The third prismatic battery; in: The first cooling segment partially surrounds the first prismatic battery; the second cooling segment partially surrounds the second prismatic battery; and A third cooling section of the cooling jacket partially surrounds the third prismatic cell.

8. The prismatic battery cooling system of claim 7, further comprising: a first thermal insulation barrier located between and in direct contact with the first cooling section and the second cooling section; as well as A second thermal insulation barrier is located between and in direct contact with the second cooling section and the third cooling section.

9. The prismatic battery cooling system of claim 1, wherein: The cooling jacket includes a plurality of flow turbulators extending into the coolant flow channel to generate turbulent flow of the coolant, with individual flow turbulators defining one of a serpentine shape and a lug.

10. The prismatic battery cooling system of claim 1, wherein: The second face is oriented substantially perpendicular to the first face, and the third face is oriented parallel to the first face and substantially perpendicular to the second face.

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