Thermal management and exhaust systems for traction battery packs and associated methods

Abstract

The present disclosure provides a thermal management and exhaust system for a traction battery pack and associated methods. A thermal management and exhaust system for managing thermal energy levels of a traction battery pack is provided. An exemplary thermal management and exhaust system may be configured to control flow of a cooling fluid through an interior volume of a battery module based on a temperature of the cooling fluid exiting a heat exchanger plate of a traction battery pack. Thus, the proposed system is capable of more quickly and effectively reducing the temperature of the exhaust gas and hot particulates by mixing the exhaust gas with a cooling fluid, thereby substantially eliminating exhaust gas combustion and heat propagation during battery thermal events.

Description

Technical Field

[0001] The present disclosure relates generally to electrified vehicle traction battery packs and, more particularly, to thermal management and venting systems for managing thermal energy levels within a traction battery pack. Background Art

[0002] An electrified vehicle includes a traction battery pack for powering the vehicle's electric motor and other electrical loads. The traction battery pack includes a plurality of battery cells and various other battery internal components that support electric vehicle propulsion. Summary of the invention

[0003] A traction battery pack according to an exemplary aspect of the present disclosure includes, inter alia: a first battery module, the first battery module including a plurality of battery cells arranged within a first internal volume; a heat exchanger plate, the heat exchanger plate positioned in thermal contact with the plurality of battery cells; a first intake manifold, the first intake manifold being fluidly connected to the first internal volume; a second intake manifold, the second intake manifold being fluidly connected to the heat exchanger plate; a flow control valve, the flow control valve being configured to selectively control the flow of a cooling fluid to at least one of the first intake manifold or the second intake manifold; and a control module, the control module being programmed to control a position of the flow control valve based on a temperature of the cooling fluid exiting the heat exchanger plate.

[0004] In another non-limiting embodiment of the foregoing traction battery pack, the second battery module includes a second internal volume that is fluidly isolated from the first internal volume.

[0005] In another non-limiting embodiment of any of the foregoing traction battery packs, the first intake manifold is fluidly connected to the second interior volume.

[0006] In another non-limiting embodiment of any of the foregoing traction battery packs, a first intake runner fluidly connects the first intake manifold to the first interior volume. A second intake runner fluidly connects the first intake manifold to the second interior volume.

[0007] In another non-limiting embodiment of any of the foregoing traction battery packs, a first exhaust manifold is fluidly connected to the first interior volume via a first exhaust runner. A second exhaust manifold is fluidly connected to the second interior volume via a second exhaust runner.

[0008] In another non-limiting embodiment of any of the foregoing traction battery packs, a first intake runner fluidly connects the first intake manifold to the first interior volume.

[0009] In another non-limiting embodiment of any of the foregoing traction battery packs, a pressure activated valve is installed in the first intake runner.

[0010] In another non-limiting embodiment of any of the foregoing traction battery packs, the control module is programmed to command the flow control valve to a first position to direct the cooling fluid to flow through the second intake manifold and not through the first intake manifold when the temperature of the cooling fluid exiting the heat exchanger plate is below a predefined temperature threshold.

[0011] In another non-limiting embodiment of any of the foregoing traction battery packs, the control module is programmed to command the flow control valve to a second position to direct the cooling fluid through the first intake manifold and not through the second intake manifold when the temperature of the cooling fluid exiting the heat exchanger plate is greater than or equal to a predefined temperature threshold.

[0012] In another non-limiting embodiment of any of the foregoing traction battery packs, the control module is programmed to command the flow control valve to a position to apportion the flow of the cooling fluid between the first intake manifold and the second intake manifold when the temperature of the cooling fluid exiting the heat exchanger plate is greater than or equal to a predefined temperature threshold.

[0013] In another non-limiting embodiment of any of the foregoing traction battery packs, a temperature sensor is positioned within or near a cooling fluid outlet of the heat exchanger plate and is configured to sense the temperature.

[0014] In another non-limiting embodiment of any of the foregoing traction battery packs, a thermal interface material is configured to maintain thermal contact between the plurality of battery cells and the heat exchanger plate.

[0015] In another non-limiting embodiment of any of the foregoing traction battery packs, a first exhaust manifold is fluidly connected to the first interior volume via a first exhaust runner.

[0016] In another non-limiting embodiment of any of the foregoing traction battery packs, the first exhaust manifold is configured to exhaust the cooling fluid and battery exhaust byproducts from the first interior volume during a battery thermal event.

[0017] In another non-limiting embodiment of any of the foregoing traction battery packs, a second intake manifold is fluidly connected to an internal cooling circuit of the heat exchanger plate.

[0018] A traction battery pack according to another exemplary aspect of the present disclosure includes, inter alia: a first battery module, the first battery module including a plurality of battery cells arranged within a first internal volume; a first cooling fluid inlet, the first cooling fluid inlet being configured to receive a first cooling fluid; a first intake manifold, the first intake manifold being fluidly connected to the first internal volume and being configured to receive the first cooling fluid from the first cooling fluid inlet; a second cooling fluid inlet, the second cooling fluid inlet being configured to receive a second cooling fluid; a heat exchanger plate, the heat exchanger plate being positioned in thermal contact with the plurality of battery cells and being configured to receive the second cooling fluid from the second cooling fluid inlet; and a control module, the control module being programmed to control the flow of the first cooling fluid from the first cooling fluid inlet into the first intake manifold based on a temperature of the second cooling fluid exiting the heat exchanger plate.

[0019] In another non-limiting embodiment of the foregoing traction battery pack, the first cooling fluid is a dielectric fluid and the second cooling fluid is a coolant.

[0020] In another non-limiting embodiment of any of the foregoing traction battery packs, the second battery module includes a second internal volume that is fluidly isolated from the first internal volume.

[0021] In another non-limiting embodiment of any of the foregoing traction battery packs, the control module is programmed to command the first cooling fluid to flow into the first intake manifold when the temperature of the second cooling fluid exiting the heat exchanger plate is greater than or equal to a predefined temperature threshold.

[0022] In another non-limiting embodiment of any of the foregoing traction battery packs, the control module is programmed to prevent the first cooling fluid from flowing into the first intake manifold when the temperature of the second cooling fluid exiting the heat exchanger plate is below a predefined temperature threshold.

[0023] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings (including any of their various aspects or corresponding individual features) may be adopted independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible.

[0024] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 An electrified vehicle is schematically shown.

[0026] Figure 2 The thermal management and exhaust system for a traction battery pack is shown.

[0027] Figure 3 Schematically shows during the first operating mode Figure 2 Thermal management and exhaust system operation.

[0028] Figure 4A Schematically shows during the second operating mode Figure 2 Thermal management and exhaust system operation.

[0029] Figure 4B Schematically shows during the third operating mode Figure 2 Thermal management and exhaust system operation.

[0030] Figure 5 Another exemplary thermal management and exhaust system for a traction battery pack is shown.

[0031] Figure 6 Yet another exemplary thermal management and exhaust system for a traction battery pack is shown. DETAILED DESCRIPTION

[0032] The present disclosure details a thermal management and exhaust system for managing thermal energy levels of a traction battery pack. An exemplary thermal management and exhaust system may be configured to control the flow of a cooling fluid through an internal volume of a battery module based on the temperature of the cooling fluid exiting a heat exchanger plate of a traction battery pack. The proposed system is able to more quickly and efficiently reduce the temperature of exhaust gases and hot particulates by mixing the exhaust gases with a cooling fluid, thereby substantially eliminating exhaust gas combustion and heat propagation during a battery thermal event. These and other features are discussed in more detail in the following paragraphs of this detailed description.

[0033] Figure 1 An electrified vehicle 10 is schematically shown. The electrified vehicle 10 may include any type of electrified powertrain. In an embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and may be extended to other electrified vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, and the like. Therefore, although not specifically shown in the exemplary embodiment, the powertrain of the electrified vehicle 10 may be equipped with an internal combustion engine, which may be employed alone or in combination with other power sources to propel the electrified vehicle 10.

[0034] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 may alternatively be a sport utility vehicle (SUV), a van, a pickup truck, or any other vehicle configuration. Although specific component relationships are shown in the drawings of the present disclosure, the drawings are not intended to limit the present disclosure. The placement and orientation of the various components of the electrified vehicle 10 are shown schematically and may vary within the scope of the present disclosure. In addition, the various drawings attached to the present disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to emphasize certain details of a particular component or system.

[0035] In the illustrated embodiment, the electrified vehicle 10 is a pure electric vehicle that is propelled solely by electricity, such as by one or more electric machines 12, without assistance from an internal combustion engine. The electric machines 12 may operate as electric motors, generators, or both. The electric machines 12 receive electricity and may convert the electricity into torque for driving one or more wheels 14 of the electrified vehicle 10.

[0036] The voltage bus 16 may electrically couple the electric machine 12 to a traction battery pack 18. The traction battery pack 18 is an exemplary electrified vehicle battery. The traction battery pack 18 may be a high voltage traction battery pack assembly that includes a plurality of battery cells capable of outputting electrical power to power the electric machine 12 and / or other electrical loads of the electrified vehicle 10. Other types of energy storage devices and / or output devices may alternatively or additionally be used to power the electrified vehicle 10.

[0037] The traction battery pack 18 may be secured to an underbody 20 of the electrified vehicle 10 . However, the traction battery pack 18 may be located elsewhere on the electrified vehicle 10 within the scope of the present disclosure.

[0038] Figure 2 Shown with Figure 1 The traction battery pack 18 of the electrified vehicle 10 may include a plurality of battery modules 22 (e.g., a battery assembly or group of rechargeable battery cells 24) capable of outputting electrical power to power the electric machine 12 and / or other electrical loads of the electrified vehicle 10.

[0039] The battery cells 24 may be stacked side-by-side along a stacking axis to construct a group of battery cells 24 , sometimes referred to as a “cell stack.” The total number of battery modules 22 and battery cells 24 provided within the traction battery pack 18 is not intended to be limiting of the present disclosure.

[0040] In an embodiment, the battery cells 24 of each battery module 22 are prismatic lithium-ion cells. However, within the scope of the present disclosure, battery cells having other geometries (cylindrical, pouch, etc.), other chemistries (nickel metal hydride, lead acid, etc.), or both may alternatively be utilized.

[0041] The battery modules 22 may be arranged in one or more rows or one or more lines within the traction battery pack 18. In an embodiment, the traction battery pack 18 includes six battery modules 22, and each battery module 22 includes four battery cells 24 (a total of twenty-four battery cells 24). However, other configurations are possible, and thus the traction battery pack 18 may include a greater or lesser number of battery modules 22 and battery cells 24 within the scope of the present disclosure.

[0042] The battery modules 22 and various other battery internal components (e.g., bus electrical center, battery electrical control module, wiring, connectors, etc.) can be housed within the interior of the housing assembly 28 of the traction battery pack 18. Although shown schematically, the housing assembly 28 can embody a single-piece design or a multi-piece design (e.g., a housing cover and a housing tray that are combined together to establish an interior for housing the battery modules 22). The size, shape, and overall configuration of the housing assembly 28 are not intended to limit the present disclosure. In an embodiment, the housing assembly 28 provides a sealed housing around the battery modules 22 and other battery internal components of the traction battery pack 18. Thus, the housing assembly 28 provides the outermost surface of the traction battery pack 18.

[0043] Each battery module 22 is spaced and therefore fluidly isolated from the other battery modules 22 of the traction battery pack 18. Thus, gases, effluent particulates, and / or other exhaust byproducts exhausted by one of the battery cells 24 of one of the battery modules 22 cannot flow directly to another of the battery modules 22.

[0044] Each battery module 22 can be separated from the other battery modules 22 of the traction battery pack 18. For example, the battery modules 22 can be separated from each other by a separator panel 30 that establishes a housing for separating each of the battery modules 22. The separator panel 30 can be configured to prevent heat from being transferred from one battery module 22 to another battery module. The separator panel 30 can also provide a desired level of compressibility to more easily position the battery module 22 within the housing assembly 28. The separator panel 30 can be made of any suitable insulating material, such as mica, aerogel, or any other suitable material or combination of materials.

[0045] The traction battery pack 18 may additionally include a thermal management and exhaust system 32. As further explained below, the thermal management and exhaust system 32 may be configured to thermally manage the battery module 22 during a battery thermal event and further manage battery exhaust byproducts V. A battery thermal event may occur, for example, during an overcharge condition, an overdischarge condition, or other condition, and may cause one or more of the battery cells 24 to exhaust battery exhaust byproducts V, which may include gases, effluent particulates, and / or other exhaust byproducts.

[0046] The thermal management and exhaust system 32 may include one or more heat exchanger plates 26. Each heat exchanger plate 26 may be configured as a cold plate for conducting heat away from the battery cells 24 during normal operation of the traction battery pack 18. In an embodiment, the battery modules 22 may share a common heat exchanger plate 26. However, within the scope of the present disclosure, each battery module 22 may include its own dedicated heat exchanger plate 26.

[0047] A thermal interface material 34 may be disposed between the battery cells 24 and the heat exchanger plate 26 of each battery module 22. The thermal interface material 34 may be configured to securely hold the battery cells 24 in place relative to the heat exchanger plate 26. In an embodiment, the bottom-facing surface of the battery cells 24 is in direct contact with the thermal interface material 34. However, other configurations are contemplated within the scope of the present disclosure.

[0048] The thermal interface material 34 can also be configured to maintain thermal contact between the battery cells 24 and the heat exchanger plate 26, thereby promoting thermal conductivity between these adjacent components during a heat transfer event. The heat conducted from the battery cells 24 to the heat exchanger plate 26 can then be carried away from the battery cells 24, such as by a cooling fluid F that can circulate inside the heat exchanger plate 26. In an embodiment, the cooling fluid F is a conventional type of coolant mixture, such as water mixed with ethylene glycol. However, other coolants, including gases, are contemplated within the scope of the present disclosure.

[0049] The thermal management and exhaust system 32 may additionally include a first intake manifold 36, a second intake manifold 38, a first exhaust manifold 40, a second exhaust manifold 42, a plurality of intake runners 44, and a plurality of exhaust runners 46. The first intake manifold 36 may extend horizontally over the tops of the battery modules 22 along a centerline between adjacent rows of battery modules 22, and the second intake manifold 38 may extend vertically along one of the divider panels 30 located on the outside / end of the group of battery modules 22. However, other arrangements are contemplated within the scope of the present disclosure. For purposes of the present disclosure, vertical and horizontal are referenced to the ground and are the normal orientations of the electrified vehicle 10 during operation.

[0050] The first exhaust manifold 40 and the second exhaust manifold 42 may each extend horizontally along another of the divider panels 30 located on the outside / end of the group of battery modules 22. In some implementations, at least a portion of each of the first exhaust manifold 40 and the second exhaust manifold 42 may extend outside of the housing assembly 28 of the traction battery pack 18. A first portion (e.g., a first row) of the battery modules 22 may be fluidly connected to the first exhaust manifold 40, and a second portion (e.g., a second row) of the battery modules 22 may be fluidly connected to the second exhaust manifold 42.

[0051] The intake runners 44 may be fluidly connected to the first intake manifold 36, and each exhaust runner 46 may be fluidly connected to the first exhaust manifold 40 or the second exhaust manifold 42. Each intake runner 44 and each exhaust runner 46 may also be fluidly connected to the interior volume 48 of one of the battery modules 22. Within the scope of the present disclosure, the intake runners 44 and the exhaust runners 46 may be configured as a plurality of aligned holes formed through adjacent components, or as conduits or tubes connected between adjacent components.

[0052] For example, the first intake manifold 36 and the second intake manifold 38 may each be fluidly connected to a cooling fluid inlet 50 configured to receive cooling fluid F, such as from a reservoir (not shown). In some implementations, at least a portion of the cooling fluid inlet 50 may extend to a location external to the housing assembly 28 .

[0053] During some operating modes, the cooling fluid F may be selectively routed through the first intake manifold 36 before being divided into the plurality of intake runners 44. The cooling fluid F may then enter the interior volume 48 of each battery module 22 individually through the intake runners 44. As the cooling fluid F flows through the interior volume 48 of each battery module 22, the cooling fluid may absorb heat from the battery cells 24 through convective heat transfer, thereby removing excess heat and stabilizing the temperature of the battery cells 24. The cooling fluid F may exit each battery module 22 through the exhaust runners 46 before merging into the first exhaust manifold 40 or the second exhaust manifold 42. During a battery thermal event, battery exhaust byproducts V may also be exhausted from one or more of the battery modules 22 via the first exhaust manifold 40 and / or the second exhaust manifold 42.

[0054] During other operating modes, the cooling fluid F may be selectively routed through the second intake manifold 38, which is fluidly connected to the heat exchanger plate 26, instead of through the first intake manifold 36. The cooling fluid F may flow through the second intake manifold 38 and then enter the internal cooling circuit 52 of the heat exchanger plate 26. As the cooling fluid F circulates through the internal cooling circuit 52, the cooling fluid may absorb heat generated within the battery cells 24 and then be discharged from the heat exchanger plate 26 through the cooling fluid outlet 54.

[0055] The thermal management and exhaust system 32 may also include a flow control valve 56, a temperature sensor 58, and a control module 60. The flow control valve 56 may be fluidly connected to the cooling fluid inlet 50, the first intake manifold 36, and the second intake manifold 38, and may be configured to control the flow of cooling fluid F allowed into each of the first intake manifold 36 and the second intake manifold 38. The flow control valve 56 may be a multi-position solenoid valve (herein, a three-way valve) or any other suitable type of valve.

[0056] The temperature sensor 58 may be configured to sense the temperature of the cooling fluid F. In an embodiment, the temperature sensor 58 is disposed in or near the cooling fluid outlet 54 of the heat exchanger plate 26 . Thus, the temperature sensor 58 may be arranged to sense the temperature of the cooling fluid F exiting the heat exchanger plate 26 .

[0057] The control module 60 may be operably connected to the flow control valve 56 and the temperature sensor 58, and may be programmed to control the operation of the thermal management and exhaust system 32. The control module 60 may include both hardware and software, and may be part of an overall vehicle control system, such as a vehicle system controller (VSC), or alternatively may be an independent controller or set of controllers separate from the VSC. Therefore, it should be understood that within the scope of the present disclosure, the control module 60 and one or more additional controllers operably coupled thereto may be collectively referred to as a "control module."

[0058] The control module 60 may be programmed with executable instructions for interfacing with and commanding the operation of various components of the thermal management and exhaust system 32 as part of an overall control strategy for controlling the flow path of the cooling fluid F. The control module 60 may include a processor 62 and a non-transitory memory 64 for executing various control strategies and modes associated with the thermal management and exhaust system 32. The processor 62 may be a custom or commercially available processor, a central processing unit (CPU), or generally any device for executing software instructions. The memory 64 may include any one or a combination of volatile memory elements and / or non-volatile memory elements. The processor 62 may be operatively connected to the memory 64 and may be configured to execute one or more programs stored in the memory 64 based on various inputs received from other devices associated with the thermal management and exhaust system 32 (e.g., the temperature sensor 58).

[0059] Temperature sensor 58 may be configured to periodically provide control module 60 with an input signal indicative of the temperature of cooling fluid F exiting heat exchanger plate 26. In response to receiving the input signal, control module 60 may control the position of flow control valve 56 to achieve a desired flow path for cooling fluid F.

[0060] For example, Figure 3 Schematically illustrated in FIG. 1 is a first operating mode that may be commanded by the control module 60. The first operating mode may be considered a default mode of the thermal management and exhaust system 32 and may occur when the temperature input signal from the temperature sensor 58 indicates that the temperature of the cooling fluid F is below a predefined temperature threshold (e.g., approximately 60 degrees Celsius). When this occurs, the control module 60 may command the flow control valve 56 to a first position to direct the cooling fluid F from the cooling fluid inlet 50 into the second intake manifold 38. Thus, the cooling fluid F may flow through the internal cooling circuit 52 of the heat exchanger plate 26 to thermally manage the battery cells 24 during normal operating conditions of the traction battery pack 18. During the first operating mode, the cooling fluid F is prevented from flowing into the first intake manifold 36 by the flow control valve 56.

[0061] Figure 4A Schematically illustrated in FIG. 2 is a second operating mode that can be commanded by the control module 60. The second operating mode can be specifically adapted to respond to a battery thermal event that may occur within one or more of the battery modules 22. For example, when the temperature input signal from the temperature sensor 58 indicates that the temperature is greater than or equal to a predefined temperature threshold (e.g., approximately 60 degrees Celsius), the control module 60 can command the flow control valve 56 to a second position to direct the cooling fluid F from the cooling fluid inlet 50 into the first intake manifold 36. Thus, the cooling fluid F can flow through the intake manifold 44 and then into the internal volume 48 of each battery module 22 to quickly and efficiently carry away excess heat and stabilize the temperature of the battery cells 24, and exhaust battery exhaust byproducts V from one or more of the battery modules 22 that are experiencing a battery thermal event (e.g., through the first exhaust manifold 40 and / or the second exhaust manifold 42). During the second operating mode, the cooling fluid F is prevented from flowing into the second intake manifold 38 by the flow control valve 56.

[0062] Figure 4B, which may be commanded by the control module 60. The third operating mode may be specifically adapted to respond to battery thermal events that may occur within one or more of the battery modules 22. For example, when the temperature input signal from the temperature sensor 58 indicates that the temperature is greater than or equal to a predefined temperature threshold (e.g., approximately 60 degrees Celsius), the control module 60 may command the flow control valve 56 to a third position to divide the flow of the cooling fluid F from the cooling fluid inlet 50 into a first portion P1 and a second portion P2, the first portion being directed into the first intake manifold 36, while the second portion is simultaneously directed into the second manifold 38. In an embodiment, the first portion P1 is approximately 30% of the cooling fluid F, and the second portion is approximately 70% of the cooling fluid F. However, other amounts are possible. Thus, a first portion P1 of the cooling fluid F can flow through the intake manifold 44 and then enter the internal volume 48 of each battery module 22 to quickly and efficiently remove excess heat and stabilize the temperature of the battery cells 24, and exhaust battery exhaust byproducts V from one or more of the battery modules 22 that are experiencing a battery thermal event (e.g., through the first exhaust manifold 40 and / or the second exhaust manifold 42), and a second portion P2 of the cooling fluid F can simultaneously flow through the internal cooling loop 52 of the heat exchanger plate 26 to thermally manage the battery cells 24 during the third operating mode.

[0063] Figure 5 Another exemplary thermal management and exhaust system 132 that may be employed by the traction battery pack 18 is shown. The thermal management and exhaust system 132 is similar to the thermal management and exhaust system 32 described above. However, in this embodiment, a pressure activated valve 66 may be installed in each of the intake runners 44 that fluidly connect the first intake manifold 36 to each of the battery modules 22.

[0064] Each pressure-activated valve 66 may be configured to rupture when the pressure within the battery module 22 exceeds a predefined pressure threshold (e.g., approximately 1 psi) to connect the interior volume 48 of the battery module 22 experiencing the battery thermal event to the first intake manifold 36. When this condition occurs, all of the cooling fluid F may be delivered directly to the battery module 22 experiencing the battery thermal event to maximize cooling performance and exhaust battery exhaust byproducts V from the battery module 22 more quickly (e.g., through the first exhaust manifold 40 and / or the second exhaust manifold 42), and the remaining battery modules 22 that are not experiencing the battery thermal event will not receive the cooling fluid F.

[0065] Figure 6Still another exemplary thermal management and venting system 232 that may be employed by the traction battery pack 18 is shown. In this embodiment, the features of the flow control valve and the second intake manifold are removed from the thermal management and venting system 232. The first cooling fluid inlet 50A may be fluidly connected to the first intake manifold 36, and the second cooling fluid inlet 50B may be fluidly connected to the internal cooling circuit 52 of the heat exchanger plate 26.

[0066] During the first operation, which may occur when the temperature input signal from the temperature sensor 58 indicates that the temperature of the cooling fluid F is below a predefined temperature threshold (e.g., approximately 60 degrees Celsius), the control module 60 may continue to command the cooling fluid F to flow from the second cooling fluid inlet 50B into the heat exchanger plate 26. Thus, the cooling fluid F may flow through the internal cooling circuit 52 of the heat exchanger plate 26 to thermally manage the battery cells 24 during normal operating conditions of the traction battery pack 18. Fluid flow through the first intake manifold 36 is prevented during the first operating mode.

[0067] During the second operating mode, which may occur when the temperature input signal from the temperature sensor 58 indicates that the temperature is greater than or equal to a predefined temperature threshold (e.g., about 60 degrees Celsius), the control module 60 may command the flow of another cooling fluid F2 to direct the cooling fluid F2 from the first cooling fluid inlet 50A into the first intake manifold 36. Thus, the cooling fluid F2 may flow through the intake runners 44 and then enter the internal volume 48 of each battery module 22 to quickly and efficiently remove excess heat and stabilize the temperature of the battery cells 24, and exhaust battery exhaust byproducts V from one or more of the battery modules 22 that are experiencing a battery thermal event.

[0068] The exemplary traction battery pack of the present disclosure includes a thermal management and exhaust system for providing enhanced battery cell thermal management and exhaust gas management. Thus, the proposed system and method can control the flow of cooling fluid through the system by mixing the exhaust gas with the cooling fluid to more quickly and effectively reduce the temperature of the exhaust gas and hot particulates, thereby substantially eliminating exhaust gas combustion and heat propagation during battery thermal events.

[0069] Although different non-limiting embodiments are shown as having specific components or steps, the embodiments of the present disclosure are not limited to these specific combinations. Some components or features from any one of the non-limiting embodiments may be used in combination with features or components from any one of the other non-limiting embodiments.

[0070] It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings.It should be understood that although particular component arrangements are disclosed and shown in these exemplary embodiments, other arrangements may also benefit from the teachings of the present disclosure.

[0071] The foregoing description should be interpreted as illustrative and not in any limiting sense. It will be appreciated by those skilled in the art that certain modifications may occur within the scope of the present disclosure. For these reasons, the attached claims should be studied to determine the true scope and content of the present disclosure.

Claims

1. A traction battery pack, comprising: a first battery module comprising a plurality of battery cells arranged within a first internal volume; a heat exchanger plate positioned in thermal contact with the plurality of battery cells; a first intake manifold fluidly connected to the first interior volume; a second intake manifold fluidly connected to the heat exchanger plate; a flow control valve configured to selectively control the flow of cooling fluid to the first intake manifold or the second intake manifold; as well as A control module is programmed to control a position of the flow control valve based on a temperature of the cooling fluid exiting the heat exchanger plate.

2. The traction battery pack of claim 1 , comprising a second battery module, the second battery module comprising a second internal volume, the second internal volume being fluidly isolated from the first internal volume.

3. The traction battery pack of claim 2, wherein the first intake manifold is fluidly connected to the second interior volume.

4. The traction battery pack of claim 3, comprising a first intake runner fluidly connecting the first intake manifold to the first internal volume, and further comprising a second intake runner fluidly connecting the first intake manifold to the second internal volume, and optionally, comprising a first exhaust manifold fluidly connecting the first exhaust manifold to the first internal volume via a first exhaust runner, and further comprising a second exhaust manifold fluidly connecting the second internal volume via a second exhaust runner.

5. A traction battery pack as claimed in any preceding claim, comprising a first intake runner fluidly connecting the first intake manifold to the first internal volume and, optionally, comprising a pressure activated valve mounted within the first intake runner.

6. A traction battery pack as claimed in any preceding claim, wherein the control module is programmed to command the flow control valve to a first position to direct the cooling fluid to flow through the second intake manifold and away from the first intake manifold when the temperature of the cooling fluid exiting the heat exchanger plate is below a predefined temperature threshold, and optionally wherein the control module is further programmed to command the flow control valve to a second position to direct the cooling fluid to flow through the first intake manifold and away from the second intake manifold when the temperature of the cooling fluid exiting the heat exchanger plate is greater than or equal to the predefined temperature threshold.

7. A traction battery pack as claimed in any preceding claim, wherein said control module is programmed to command said flow control valve to a position to distribute said flow of said cooling fluid between said first intake manifold and said second intake manifold when said temperature of said cooling fluid exiting said heat exchanger plate is greater than or equal to a predefined temperature threshold.

8. A traction battery pack as claimed in any preceding claim, comprising a temperature sensor positioned in or adjacent a cooling fluid outlet of the heat exchanger plate and configured to sense the temperature.

9. A traction battery pack as claimed in any preceding claim, comprising a thermal interface material configured to maintain the thermal contact between the plurality of battery cells and the heat exchanger plate.

10. A traction battery pack as claimed in any preceding claim, comprising a first exhaust manifold fluidly connected to the first internal volume via a first exhaust runner, and optionally wherein the first exhaust manifold is configured to exhaust the cooling fluid and battery exhaust byproducts from the first internal volume during a battery thermal event.

11. A traction battery pack as claimed in any preceding claim, wherein the second intake manifold is fluidly connected to an internal cooling circuit of the heat exchanger plate.

12. A traction battery pack, comprising: a first battery module comprising a plurality of battery cells arranged within a first internal volume; a first cooling fluid inlet configured to receive a first cooling fluid; a first intake manifold fluidly connected to the first interior volume and configured to receive the first cooling fluid from the first cooling fluid inlet; a second cooling fluid inlet configured to receive a second cooling fluid; a heat exchanger plate positioned in thermal contact with the plurality of battery cells and configured to receive the second cooling fluid from the second cooling fluid inlet; as well as A control module programmed to control flow of the first cooling fluid from the first cooling fluid inlet into the first intake manifold based on a temperature of the second cooling fluid exiting the heat exchanger plate.

13. The traction battery pack of claim 12, wherein the first cooling fluid is a dielectric fluid and the second cooling fluid is a coolant.

14. A traction battery pack as claimed in claim 12 or 13, comprising a second battery module, the second battery module comprising a second internal volume, the second internal volume being fluidly isolated from the first internal volume.

15. The traction battery pack of claims 12-14, wherein the control module is programmed to command the first cooling fluid to flow into the first intake manifold when the temperature of the second cooling fluid exiting the heat exchanger plate is greater than or equal to a predefined temperature threshold, and optionally wherein the control module is further programmed to prevent the first cooling fluid from flowing into the first intake manifold when the temperature of the second cooling fluid exiting the heat exchanger plate is less than the predefined temperature threshold.

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