Battery assembly with end cover exhaust port

Abstract

The battery assembly comprises a battery panel and a battery unit. And the battery units are supported in the battery panel and are arranged in multiple rows. The battery assembly includes a plurality of vents, and each of the plurality of vents is defined by a bottom of a battery panel, a support, and a battery tray. Each exhaust port extends a length of each row. The end cap is coupled with a structural plate of the battery panel and includes a plurality of apertures, a baffle, and an exhaust passage. The baffle has a baffle wall disposed opposite the plurality of apertures. The baffle walls extend to the top and bottom of the elongated body. An exhaust passage extends along the baffle and is configured to carry exhaust gases. The battery assembly also includes a battery pack vent for venting the vent gas from the end cap.

Description

Technical Field

[0001] The present disclosure relates to a battery cell, and more particularly to a battery cell assembly capable of thermal management. Background Art

[0002] A rechargeable energy storage system (RESS), such as a prismatic battery assembly, typically includes multiple electrode stacks or cells. Each electrode stack includes an anode and a cathode separated by an electrically insulating separator material. The electrode stacks are adjacent to each other and are typically placed in a housing or enclosure to protect the electrode stacks from the surrounding environment. The enclosure also serves to contain the electrolyte within the enclosure and around the electrode stacks. Electrode stacks in a RESS may experience uncontrolled thermal events known as thermal runaway propagation (TRP). During a TRP event, the electrode stack may exhaust gases that may be heated as they flow toward the enclosure or battery stack exhaust port. The increased temperature of the heated gases caused by a TRP event may result in an increase in the temperature of the gases that are exhausted and mixed with ambient air outside the RESS.

[0003] Although methods and systems for minimizing the temperature of exhaust gases from a RESS during a TRP event exist in the prior art and achieve their specific purposes, there is still a need for a new and improved system for thermal management of exhaust gases. Therefore, a battery with cooling capabilities for heated exhaust gases is needed. Summary of the invention

[0004] According to several aspects of the present disclosure, a battery assembly having an end cap for thermal management is provided. The battery assembly includes a battery tray, a battery plate, and a plurality of battery cells. The battery tray has a tray top surface. The battery plate is supported by the battery tray. The battery plate has at least one side wall and a bottom. A plurality of structural plates are coupled to the bottom, and the battery plate has a plurality of supports for supporting the bottom. A plurality of battery cells are supported in the battery plate. Each of the plurality of battery cells has a cell exhaust port, and the plurality of battery cells are arranged in a plurality of rows defined by a plurality of structural plates. The battery assembly includes a plurality of exhaust ports, and each of the plurality of exhaust ports is defined by the bottom of the battery plate, one of the plurality of supports, another of the plurality of supports, and the tray top surface. Each exhaust port extends the length of each of the plurality of rows, and each of the cell exhaust ports in the plurality of battery cells is in fluid communication with each of the plurality of exhaust ports. The battery assembly includes an end cap having an elongated body. The elongated body has a length, a top, and a bottom. The end cap includes a plurality of holes, a baffle, and an exhaust channel. The plurality of holes are arranged along the length of the elongated body. The baffle has a baffle wall extending the length of the elongated body. The baffle wall extends to the top and bottom of the elongated body and is coupled to the first end of the elongated body. An exhaust passage is defined by the baffle and the elongated body, extends along the baffle, and is configured to carry exhaust gas. The battery assembly also includes a battery pack exhaust port, which is disposed near the first end of the elongated body and is configured to exhaust the exhaust gas from the end cap.

[0005] According to another aspect of the present disclosure, an end cap is coupled to a plurality of structural panels of a battery panel.

[0006] According to another aspect of the present disclosure, the baffle wall is disposed opposite the plurality of apertures.

[0007] According to another aspect of the present disclosure, a battery assembly includes a baffle configured in a linear configuration.

[0008] According to another aspect of the present disclosure, a battery assembly includes a baffle formed from a steel stamping.

[0009] According to another aspect of the present disclosure, the battery assembly further includes an external channel coupled to the outer side of the side wall of the battery plate. The external channel has a channel inlet and a channel exhaust port. The channel inlet is arranged to be close to the battery pack exhaust port and receive exhaust gas from the battery pack exhaust port. The channel exhaust port exhausts the exhaust gas.

[0010] According to another aspect of the present disclosure, a battery assembly includes an external channel configured in a non-direct manner.

[0011] According to another aspect of the present disclosure, a battery assembly includes an outer channel configured in a wave shape.

[0012] According to several aspects of the present disclosure, a battery assembly having an external channel for thermal management is provided. The battery assembly includes a battery tray, a battery plate, and a plurality of battery cells. The battery tray has a tray top surface. The battery plate is supported by the battery tray. The battery plate has at least one side wall and a bottom. A plurality of structural plates are coupled to the bottom, and the battery plate has a plurality of supports for supporting the bottom. A plurality of battery cells are supported in the battery plate. Each of the plurality of battery cells has a cell exhaust port, and the plurality of battery cells are arranged in a plurality of rows defined by a plurality of structural plates. The battery assembly includes a plurality of exhaust ports, and each of the plurality of exhaust ports is defined by the bottom of the battery plate, one of the plurality of supports, another of the plurality of supports, and the tray top surface. Each exhaust port extends the length of each of the plurality of rows, and each of the cell exhaust ports in the plurality of battery cells is in fluid communication with each of the plurality of exhaust ports. The battery assembly includes an external channel coupled to the outer side of the side wall of the battery plate. The external channel has a channel inlet and a channel exhaust port. The channel inlet is arranged to be close to the battery pack exhaust port and receive exhaust gas from the battery pack exhaust port. The channel exhaust port exhausts the exhaust gas.

[0013] According to another aspect of the present disclosure, a battery assembly includes a plurality of vents extending along the front and rear of the battery.

[0014] According to another aspect of the present disclosure, the battery assembly also includes an end cap having an elongated body. The elongated body has a length, a top and a bottom, and the end cap is coupled to a plurality of structural plates of the battery panel. The end cap includes a plurality of holes, a baffle, and an exhaust passage. The plurality of holes are arranged along the length of the elongated body. The baffle has a baffle wall extending the length of the elongated body, and the baffle wall is arranged opposite to the plurality of holes. The baffle wall extends to the top and bottom of the elongated body and is coupled to the first end of the elongated body. The exhaust passage is defined by the baffle and the elongated body, extends along the baffle, and is configured to carry exhaust gas. The battery assembly also includes a battery pack exhaust port, which is arranged near the first end of the elongated body and is configured to exhaust the exhaust gas from the end cap.

[0015] According to another aspect of the present disclosure, a battery assembly includes an end cap that provides fluid communication of exhaust gases from a plurality of exhaust ports to a battery pack exhaust port.

[0016] According to another aspect of the present disclosure, a battery assembly includes end caps perpendicular to the plurality of rows.

[0017] According to several aspects of the present disclosure, a battery assembly having an end cap and an external channel for thermal management is provided. The battery assembly includes a battery tray, a battery plate, and a plurality of battery cells. The battery tray has a tray top surface. The battery plate is supported by the battery tray. The battery plate has at least one side wall and a bottom. A plurality of structural plates are coupled to the bottom, and the battery plate has a plurality of supports for supporting the bottom. A plurality of battery cells are supported in the battery plate. Each of the plurality of battery cells has a cell exhaust port, and the plurality of battery cells are arranged in a plurality of rows defined by a plurality of structural plates. The battery assembly includes a plurality of exhaust ports, and each of the plurality of exhaust ports is defined by the bottom of the battery plate, one of the plurality of supports, another of the plurality of supports, and the tray top surface. Each exhaust port extends the length of each of the plurality of rows, and each of the cell exhaust ports in the plurality of battery cells is in fluid communication with each of the plurality of exhaust ports. The battery assembly includes an end cap having an elongated body. The elongated body has a length, a top, and a bottom, and the end cap is coupled to the plurality of structural plates of the battery plate. The end cap includes a plurality of holes, a baffle, and an exhaust channel. A plurality of holes are arranged along the length of the elongated body. The baffle has a baffle wall extending the length of the elongated body, and the baffle wall is arranged opposite to the plurality of holes. The baffle wall extends to the top and bottom of the elongated body and is connected to the first end of the elongated body. The exhaust channel is defined by the baffle and the elongated body, extends along the baffle, and is configured to carry exhaust gas. The battery assembly also includes a battery pack exhaust port, which is arranged near the first end of the elongated body and is configured to exhaust the exhaust gas from the end cap. The battery assembly includes an external channel connected to the outer side of the side wall of the battery plate. The external channel has a channel inlet and a channel exhaust port. The channel inlet is arranged to be close to the battery pack exhaust port and receives the exhaust gas from the battery pack exhaust port. The channel exhaust port exhausts the exhaust gas.

[0018] According to another aspect of the present disclosure, a battery assembly includes an end cap in fluid communication from a plurality of vents to a battery pack vent.

[0019] According to another aspect of the present disclosure, a battery assembly includes end caps welded to a tray top surface, a plurality of structural plates, and a bottom.

[0020] According to another aspect of the present disclosure, a battery assembly includes a baffle configured in a linear configuration.

[0021] According to another aspect of the present disclosure, a battery assembly includes a baffle formed from a steel stamping.

[0022] According to another aspect of the present disclosure, a battery assembly includes an external channel configured in a non-direct manner.

[0023] According to another aspect of the present disclosure, a battery assembly includes an outer channel configured in a wave shape. 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 an environmental view of an example of a vehicle having a battery assembly configured to passively cool and exhaust exhaust gases during a TRP event according to the present disclosure.

[0026] Figure 2 According to the present disclosure, Figure 1 A perspective view of a battery assembly is shown wherein the battery assembly is mechanically coupled to a battery tray and includes end caps and external channels.

[0027] Figure 3 According to the present disclosure, Figure 2 A partial side cross-sectional view of a battery cell and a vent in a battery assembly is shown, wherein the vent is defined by a bottom wall of a battery plate, first and second supports, and a battery tray.

[0028] Figure 4A According to the present disclosure, Figure 2 A partial perspective view of a portion of a battery assembly is shown with an end cap disposed on one side of the battery.

[0029] Figure 4B According to the present disclosure, Figure 4A An enlarged side cross-sectional view of a portion of the end cap is shown.

[0030] Figure 5 According to the present disclosure, Figure 2 and a top view of the end cap shown in FIG. 4 , wherein the end cap includes a baffle.

[0031] Fig. 6A According to the present disclosure, Figure 2 A side elevation view of an outer channel is shown, wherein the outer channel includes a plate member having curved protruding walls in a wavy configuration.

[0032] Figure 6B According to the present disclosure Fig. 6A A cross-sectional enlargement of the external channel is shown. DETAILED DESCRIPTION

[0033] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0034] refer to Figure 1, a vehicle 10 is shown according to the principles of the present disclosure, the vehicle 10 having a battery assembly 12 configured to cool gases exhausted from the battery assembly 12. The battery assembly 12 is shown with an exemplary vehicle 10, and the vehicle 10 is an electric vehicle or a hybrid vehicle having wheels 14 driven by a motor / inverter. The motor / inverter receives power from the battery assembly 12. Although the vehicle 10 is shown as a passenger road vehicle, it should be understood that the battery assembly 12 can be used with various other types of vehicles. For example, the battery assembly 12 can be used in a marine vehicle (such as a ship) or an aviation vehicle (such as a drone or a passenger plane). In addition, the battery assembly 12 can be used as a stationary power source that is separate and independent from the vehicle.

[0035] Reference Figure 2 , a perspective view of the battery assembly 12 is shown, generally including a battery tray 16, a battery panel 20, and a plurality of battery cells 22. The battery tray 16 is a generally planar member having a tray top surface 18. The battery tray 16 is supported by the vehicle 10 and mounted to the vehicle 10 using mechanical fasteners 28, such as bolts (not shown) that pass through holes in the battery tray 16. The battery tray 16 provides structural support for the battery panel 20.

[0036] The battery panel 20 provides structural support and containment for the plurality of battery cells 22 of the battery assembly 12. The battery panel 20 includes sidewalls 24 and a bottom 26. The sidewalls 24 extend around the perimeter of the bottom 26. In addition, the battery panel 20 includes a plurality of support members 30 extending from the bottom 26. The plurality of support members 30 are disposed on and coupled (e.g., welded) to the tray top surface 18 of the battery tray 16. For example, the plurality of support members 30 may include a plurality of flanges positioned between the tray top surface 18 and the bottom 26 of the battery panel 20 and coupled to the tray top surface 18 and the bottom 26.

[0037] Continue to refer Figure 2 , a plurality of battery cells 22 are supported on a bottom 26 of the battery panel 20. Each of the plurality of battery cells 22 has a cell exhaust port 32 for releasing exhaust gas when a TRP event occurs. A plurality of structural plates 36 define a plurality of rows 34 in the battery panel 20. The structural plates 36 are coupled to the bottom 26 of the battery panel 20. A portion of the plurality of battery cells 22 is arranged and disposed in one of the plurality of rows 34. In the example Figure 2 In the example shown, the rows 34 are arranged in a front-to-back configuration, wherein the rows extend from the battery assembly 12 and the front 38 of the vehicle 10 along the length of the panel 20 to the rear 40 of the panel 20 (away from the front 38). It should be appreciated that the rows 34 may be arranged in other configurations, such as extending along the width of the panel 20 (e.g., perpendicular to the front-to-back direction).

[0038] In such Figure 2In the example shown, the battery cells 22 are prismatic cells whose chemistry is enclosed in a rigid rectangular housing. The rectangular housing allows for efficient stacking of the battery cells 22 in the battery plate 20. In other cases, the battery assembly 12 may include, for example, cylindrical lithium-ion battery cells and / or soft pack batteries. It should be understood that any type of battery cell 22 may be employed. The structural plate 36 provides structural support and separation between the rows 34.

[0039] refer to Figure 3 According to one aspect of the present disclosure, Figure 2 A cross-sectional view of the battery tray 16, battery panel 20, and battery cells 22 is shown. A vent 42 corresponds to each row 34 in the battery panel 20 to exhaust gas from each of the plurality of battery cells 22 in each row 34 during a TRP event. Each vent 42 is defined by the bottom 26 of the battery panel 20, one of the plurality of supports 30 (e.g., first support 30A), another of the plurality of supports 30 (e.g., second support 30B), and the tray top surface 18 of the battery tray 16. Figure 3 , the first support member 30A and the second support member 30B are shown as flanges disposed between the bottom 26 and the tray top surface 18. Each vent 42 extends along the length of each of the plurality of rows 34. In addition, each cell vent 32 in the plurality of battery cells 22 is in fluid communication with each of the plurality of vents 42. When a TRP event occurs, the generated gas is released from at least one cell vent 32 of the plurality of battery cells 22 to one of the plurality of vents 42, and the generated gas flows along the row 34 through the vent 42 and away from the plurality of battery cells 22.

[0040] Reference Figure 4A and Figure 4B , a partial perspective view of a portion of the battery assembly 12 and an enlarged side cross-sectional view of the end cap 44 are shown. The end cap 44 is a steel stamping, for example, configured to receive exhaust gas from the exhaust port 42. The end cap 44 has an elongated body 46. More specifically, the elongated body 46 has a length L, a top 48, and a bottom 50. The end cap 44 can be mechanically coupled (e.g., welded) to the bottom 26 of the battery plate 20, the structural plate 36, and the tray top surface 18.

[0041] like Figure 5 As shown, end cap 44 includes a plurality of exhaust holes 52, baffles 54, exhaust passages 56, and battery exhaust ports 58. Each of the plurality of exhaust holes 52 is disposed along length L of elongated body 46 and is in fluid communication with exhaust ports 42 to receive exhaust gas therefrom.

[0042] Continue to refer Figure 4A , Figure 4B and Figure 5, the baffle 54 has a baffle wall 60 extending along the length of the elongated body 46. The baffle wall 60 is disposed opposite the plurality of exhaust apertures 52 and extends to the top 48 and the bottom 50 of the elongated body 46. Alternatively, the baffle wall 60 is coupled (e.g., welded) to the first end 62 of the elongated body 46. The baffle 54 may be formed from a steel stamping and stamped into the end cap 44 to be integrally formed with the end cap 44. An exhaust passage 56 is defined by the baffle 54 and the elongated body 46 and extends the length of the baffle wall 60 on a first side of the baffle wall 60 relative to the exhaust apertures 52. An opening between the end of the baffle wall 60 and the end of the elongated body 46 defines an exhaust passage to the opposite side of the baffle wall 60. Thus, the exhaust passage 56 extends from the exhaust passage opening along the baffle wall 60 to the first end 62 of the elongated body 46. When the exhaust gas enters the end cap 44 from the exhaust hole 52, the exhaust gas is directed along the exhaust channel 56, as shown by arrow d, from the first end 62 of the elongated body 46 toward the second end 64 to the battery pack exhaust port 58. The presence of the baffle wall 60 causes the exhaust gas to take a longer path (i.e., along the exhaust channel 56) instead of directly reaching the battery pack exhaust port 58 in the absence of the baffle wall 60. The longer path formed by the exhaust channel 56 provides an opportunity for the exhaust gas to further cool before reaching the battery pack exhaust port 58. The battery pack exhaust port 58 is disposed near the first end 62 of the elongated body 46 and is configured to exhaust the exhaust gas from the end cap 44 through an opening or hole in the wall 24 of the battery plate 20. The exhaust channel 56 exhausts the exhaust gas through the battery pack exhaust port 58.

[0043] In an alternative aspect of the present disclosure, the battery assembly 12 may not include the end cap 44. In this aspect of the present disclosure, the exhaust gas is exhausted from the exhaust port 42 directly to the battery pack exhaust port 58 within the interior of the battery plate 20. The exhaust gas is cooled as it contacts the metal surfaces of the elongated body 46, the baffle wall 60, and other metal surfaces within the end cap 44. This cooling serves to passively cool the exhaust gas as it passes through the end cap 44.

[0044] Reference again Figure 2 And now reference Fig. 6A and Figure 6B , Fig. 6A is a side view of the battery assembly 12, Figure 6B FIG. 6 is an enlarged cross-sectional view of the outer plate 66 mechanically connected to the battery assembly 12. Fig. 6A As shown, according to another aspect of the present disclosure, an outer plate 66 is disposed on an outer surface 67 of the wall 24 of the battery panel 20. The outer plate 66 has an elongated plate member 68 having a curved protruding wall 69 (such as Figure 6B24). The external exhaust passage 65 is defined by the curved protruding wall 69 and the outer surface 67 of the wall 24. The external exhaust passage 65 has a passage inlet 70 and a passage outlet vent 74. The passage inlet 70 includes an opening or hole that communicates with the battery pack vent 58. The passage inlet 70 receives exhaust gas from the battery pack vent 58. The external exhaust passage 65 carries the exhaust gas exhausted from the battery pack vent 58.

[0045] In addition, since the external exhaust passage 65 is located outside the battery panel 20, the external exhaust passage 65 is disposed in the crash basin of the vehicle 10 and is configured as an extrudable member, thereby achieving better space utilization. Figure 2 As shown, the outer exhaust passages 65 may be in a front-to-back configuration (eg, extending parallel to the plurality of rows 34). It should be appreciated that the outer exhaust passages 65 may be oriented in other configurations (eg, perpendicular to the rows 34).

[0046] like Figure 2 and Fig. 6A As shown, the external exhaust passage 65 is arranged in a wavy or wave shape. More specifically, the external exhaust passage 65 extends from the passage inlet 70 in a serpentine shape or an alternating curved configuration. The external exhaust passage 65 guides the exhaust gas to flow in a non-direct path, which increases the surface area contacted by the exhaust gas and increases the residence time of the exhaust gas flowing through the external exhaust passage 65, thereby enhancing the cooling of the exhaust gas. It should be understood that the external passage 66 may include other configurations, such as a linear configuration. The exhaust gas is discharged from the external exhaust passage 65 through the passage outlet exhaust port 74. The passage outlet exhaust port 74 discharges the exhaust gas to the surrounding environment (such as the vehicle environment).

[0047] In some embodiments, the battery assembly 12 includes an end cap 44 and an external exhaust passage 65 for carrying and cooling the exhaust gas. However, in some embodiments, the battery assembly 12 may include an end cap 44 without an external exhaust passage 65, or the battery assembly 12 may include only an external exhaust passage 65 without an end cap 44.

[0048] This description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in many forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, as other modifications will become apparent after studying the drawings, the specification and the appended claims.

Claims

1. A battery assembly comprising: a battery tray having a tray top surface; A battery panel supported by the battery tray, wherein the battery panel has at least one side wall and a bottom, wherein a plurality of structural plates are coupled to the bottom, wherein the battery panel has a plurality of support members for supporting the bottom; supporting a plurality of battery cells within the battery panel, each of the plurality of battery cells having a cell vent, wherein the plurality of battery cells are arranged in a plurality of rows defined by the plurality of structural panels; a plurality of vents, wherein each of the plurality of vents is defined by a bottom of the battery panel, one of the plurality of supports, another of the plurality of supports, and a top surface of the tray, wherein each vent extends the length of each of the plurality of rows, wherein each cell vent of the plurality of battery cells is in fluid communication with each of the plurality of vents; An end cap having an elongated body, wherein the elongated body has a length, a top, and a bottom, wherein the end cap comprises: a plurality of holes disposed along the length of the elongated body; a baffle having a baffle wall extending the length of the elongated body, wherein the baffle wall extends to the top and bottom of the elongated body and is coupled to the first end of the elongated body; and an exhaust passage defined by the baffle and the elongated body and extending along the baffle, configured to carry exhaust gas; and A battery pack exhaust port is disposed near the first end of the elongated body and is configured to exhaust the exhaust gas from the end cap.

2. The battery assembly according to claim 1, wherein: The end caps are coupled to a plurality of structural plates of the battery panel.

3. The battery assembly according to claim 1, wherein: The baffle wall is disposed opposite to the plurality of holes.

4. The battery assembly according to claim 3, wherein: The baffle is configured in a linear configuration.

5. The battery assembly according to claim 4, wherein: The baffle is formed from a steel stamping.

6. The battery assembly according to claim 1, further comprising: An external exhaust channel connected to the outer surface of the side wall of the battery plate, wherein the external exhaust channel has a channel inlet and a channel outlet exhaust port, wherein the channel inlet is arranged to be close to the battery pack exhaust port and receive exhaust gas from the battery pack exhaust port, and wherein the channel outlet exhaust port exhausts the exhaust gas.

7. The battery assembly according to claim 6, wherein: The external exhaust passage is configured as an indirect type.

8. The battery assembly according to claim 7, wherein: The external exhaust passage is configured in a wave shape.

9. A battery assembly comprising: a battery tray having a tray top surface; A battery panel supported by the battery tray, wherein the battery panel has at least one side wall and a bottom, wherein a plurality of structural plates are coupled to the bottom, wherein the battery panel has a plurality of support members for supporting the bottom; supporting a plurality of battery cells within the battery panel, each of the plurality of battery cells having a cell vent, wherein the plurality of battery cells are arranged in a plurality of rows defined by the plurality of structural panels; a plurality of vents, wherein each of the plurality of vents is defined by a bottom of the battery panel, one of the plurality of supports, another of the plurality of supports, and a top surface of the tray, wherein each vent extends the length of each of the plurality of rows, wherein each cell vent of the plurality of battery cells is in fluid communication with each of the plurality of vents; a battery pack exhaust port, disposed on a side wall of the battery panel and configured to exhaust exhaust gas from the battery panel; and An external channel connected to the outer surface of the side wall of the battery plate, wherein the external channel has a channel inlet and a channel outlet exhaust port, wherein the channel inlet is arranged to be close to the battery pack exhaust port and receive exhaust gas from the battery pack exhaust port, and wherein the channel outlet exhaust port exhausts the exhaust gas.

10. The battery assembly according to claim 9, wherein: The plurality of exhaust ports extend front to back along the battery assembly.

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