Cooling of automotive battery pack

Abstract

A battery assembly of a vehicle includes a first unit layer including a first plurality of battery cells, a second unit layer including a second plurality of battery cells, and a cold plate between the first unit layer and the second unit layer. The cooling plate includes a plurality of coolant paths configured to flow a flow of coolant therethrough. The first plurality of battery cells contact a first side of the cold plate and the second plurality of battery cells contact a second side of the cold plate opposite the first side to cool the first plurality of battery cells and the second plurality of battery cells via a flow of coolant through the cold plate.

Description

Technical Field

[0001] The present disclosure relates to vehicles, and in particular to cooling of a battery pack of a vehicle. Background Art

[0002] High capacity batteries are used in many consumer and industrial sectors, including transportation and grid applications. High capacity batteries are known to include a plurality of battery modules, allowing flexibility of configuration and adaptation to application requirements.

[0003] Such battery packs generate heat and internal pressure when placed under load. Heat can have an adverse effect on battery efficiency and / or battery life, and the buildup of internal pressure during a thermal event in the battery can result in a shortened life of the battery pack. Therefore, removing heat and reducing internal pressure provides benefits to battery operation. Summary of the invention

[0004] In an exemplary embodiment, a battery assembly of a vehicle includes a first cell layer, a second cell layer, and a cold plate, the first cell layer including a first plurality of battery cells, the second cell layer including a second plurality of battery cells, and the cold plate is located between the first cell layer and the second cell layer. The cold plate includes a plurality of coolant paths configured to allow a coolant flow to flow therethrough. The first plurality of battery cells contact a first side of the cold plate, and the second plurality of battery cells contact a second side of the cold plate opposite to the first side, to cool the first plurality of battery cells and the second plurality of battery cells via a coolant flow through the cold plate.

[0005] In addition to one or more features described herein, the battery cells each have a first cell end and a second cell end opposite the first cell end, and the second cell end of each battery cell of the first cell layer and the second cell layer contacts the cold plate.

[0006] In addition to one or more features described herein, each battery cell includes an electrode stack in a pouch having a closure at a first cell end.

[0007] In addition to one or more features described herein, the second plurality of battery cells are inverted relative to the first plurality of battery cells.

[0008] In addition to one or more features described herein, the housing at least partially surrounds the first cell layer, the second cell layer, and the cold plate.

[0009] In addition to one or more features described herein, at least one of the first plurality of battery cells and the second plurality of battery cells is secured to the cold plate via a plurality of fasteners.

[0010] In addition to one or more features described herein, a battery disconnect unit is operably connected to one of the plurality of battery cells and is cooled by a coolant flow diverted from a cold plate via one of a fluid parallel or series connection.

[0011] In another exemplary embodiment, a vehicle includes a body and a propulsion system for driving the vehicle to move. The propulsion system includes a battery assembly that powers the propulsion system. The battery assembly includes a first unit layer, a second unit layer, and a cold plate, the first unit layer including a first plurality of battery cells, the second unit layer including a second plurality of battery cells, and the cold plate is located between the first unit layer and the second unit layer. The cold plate includes a plurality of coolant paths, and the plurality of coolant paths are configured to allow a coolant flow to flow therethrough. The first plurality of battery cells contact a first side of the cold plate, and the second plurality of battery cells contact a second side of the cold plate opposite to the first side, so as to cool the first plurality of battery cells and the second plurality of battery cells via a coolant flow passing through the cold plate.

[0012] In addition to one or more features described herein, the battery cells each have a first cell end and a second cell end opposite the first cell end, and the second cell end of each battery cell of the first cell layer and the second cell layer contacts the cold plate.

[0013] In addition to one or more features described herein, each battery cell includes an electrode stack in a pouch having a closure at a first cell end.

[0014] In addition to one or more features described herein, the second plurality of battery cells are inverted relative to the first plurality of battery cells.

[0015] In addition to one or more features described herein, the housing at least partially surrounds the first cell layer, the second cell layer, and the cold plate.

[0016] In addition to one or more features described herein, at least one of the first plurality of battery cells and the second plurality of battery cells is secured to the cold plate via a plurality of fasteners.

[0017] In addition to one or more features described herein, a battery disconnect unit is operably connected to one of the plurality of battery cells and cooled via a coolant flow.

[0018] In yet another exemplary embodiment, a method of assembling a battery assembly includes assembling a first plurality of battery cells to a first side of a cold plate. The cold plate includes a plurality of coolant paths configured to allow a coolant flow therethrough. A second plurality of battery cells is assembled to a second side of the cold plate opposite the first side. The first plurality of battery cells contacts the first side of the cold plate, and the second plurality of battery cells contacts the second side of the cold plate to cool the first plurality of battery cells and the second plurality of battery cells via the coolant flow through the cold plate.

[0019] In addition to one or more features described herein, the battery cells each have a first cell end and a second cell end opposite the first cell end, and the second cell end of each battery cell in the first and second pluralities of battery cells contacts the cold plate.

[0020] In addition to one or more features described herein, each battery cell includes an electrode stack positioned in a pouch having a closure at a first cell end.

[0021] In addition to one or more features described herein, the second plurality of battery cells are inverted relative to the first plurality of battery cells.

[0022] In addition to one or more features described herein, the first plurality of battery cells, the second plurality of battery cells, and the cold plate are enclosed in a housing.

[0023] In addition to one or more features described herein, a battery disconnect unit is operably connected to one of the plurality of battery cells to cool the cooling plate via a coolant flow.

[0024] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a schematic diagram of an embodiment of a vehicle;

[0027] Figure 2 is a partial cross-sectional view of an embodiment of a battery assembly;

[0028] Figure 3 is another partial cross-sectional view of an embodiment of a battery assembly;

[0029] Figure 4A is a first illustration of a method of assembling a battery assembly;

[0030] Figure 4B is a second illustration of a method of assembling a battery assembly; and

[0031] Figure 4C is a third illustration of a method of assembling a battery assembly. DETAILED DESCRIPTION

[0032] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0033] According to an exemplary embodiment, a vehicle according to a non-limiting example is Figure 1 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. In a non-limiting example, two of the plurality of wheels 16 are steerable. The body 12 partially defines a passenger compartment 20 having a seat 22 positioned behind an instrument panel 26. A steering controller 30 is disposed between the seat 22 and the instrument panel 26. The steering controller 30 is operated to control the orientation of the steerable wheels. The vehicle 10 includes an electric motor 34 connected to a transmission that provides power to one or more of the plurality of wheels 16. A rechargeable energy storage system (RESS) or battery assembly 38 provides power to the electric motor 34.

[0034] Reference now Figure 2 , an embodiment of a battery assembly 38 is shown. In some embodiments, the battery assembly 38 is a lithium ion battery, but those skilled in the art will readily appreciate that other suitable types of batteries may be utilized. The battery assembly 38 includes a plurality of battery cells 40 disposed in a battery housing 42 that at least partially surrounds the plurality of battery cells 40. The battery cells 40 are positioned in the battery housing 42, arranged along a tray length direction 46 and across a tray width direction 44, and arranged in at least two cell layers 48a and 48b in a tray height direction 50. Now referring to Figure 3 , each battery cell 40 includes an electrode stack 52 in a cell housing 54, and includes a first cell end 56 and a second cell end 58. In some embodiments, the battery cells 40 are "pouches" of battery cells, wherein the battery housing 54 is configured as a pouch with a closure 78, such as a zipper closure, at the first cell end 56. In some embodiments, the configuration of the battery cells 40 in the first cell layer 48a is the same as the configuration of the battery cells 40 in the second cell layer 48b.

[0035] The battery housing 42 includes a bottom panel 60 (such as a floor panel), opposing side panels 62, and a cover 64, thereby defining the battery housing 42 as at least partially surrounding the battery cells 40. In addition, the battery housing 42 includes a cold plate 66 located between the first cell layer 48a and the second cell layer 48b. The cold plate 66 includes a plate body 68 and a plurality of coolant paths 70 formed in the plate body 68. The coolant flow 72 circulates through the plurality of coolant paths 70, enters the cold plate 66 at the coolant inlet 74, and exits the cold plate 66 at the coolant outlet 76. In some embodiments, the battery assembly 38 includes a battery disconnect unit (BDU) 90 that monitors, activates, and deactivates the battery assembly 38. The BDU 90 is connected to the cold plate 66 and cools the BDU 90 using the coolant 72 transferred from the cold plate 66. The coolant 72 is delivered to the BDU 90 by connecting to the cold plate 66 in a fluid parallel or series arrangement. After flowing through the BDU 90 to cool the BDU 90 , the coolant 72 returns to the cold plate 66 .

[0036] The cold plate 66 is positioned with the first cell layer 48a and the second cell layer 48b to cool both the first cell layer 48a and the second cell layer 48b via heat energy exchange between the battery cells 40 of the first cell layer 48a and the second cell layer 48b and the flow of the coolant 72 through the cold plate 66. In particular, to promote efficient heat energy exchange and cooling of the battery cells 40, the battery cells 40b of the second cell layer 48b are inverted relative to the battery cells 40a of the first cell layer 48a. When installed in the battery housing 42, the battery cells 40a of the first cell layer 48a are all arranged so that their respective second battery ends 58 abut the cold plate 66, so that the first battery end 56 with the closure 78 is farther away from the cold plate 66 than the second battery end 58. Positioning each of the second battery ends 58 abutting the cold plate 66 improves the efficiency of heat energy transfer between the battery cells 40 of each of the cell layers 48a, 48b and the cold plate 66.

[0037] Reference now Figures 4A-4C , a method of assembling the battery assembly 38 is shown. The battery cells 40a of the first cell layer 48a are mounted to the first side 80 of the cold plate 66 via, for example, a plurality of fasteners 82, wherein the second battery end 58 abuts the first side 80, so that there is full contact between the second battery end 58 and the first side 80. Figure 4B As shown, the battery cells 40b of the second cell layer 48b are mounted to the second side 84 of the cold plate 66 opposite the first side 80 via, for example, a plurality of fasteners. The battery cells 40b are mounted so that the second ends 58 abut the second side 84, so that there is full contact between the second battery ends 58 and the second side 84. Now referring to Figure 4CThe battery cell 40 and cold plate 66 subassembly may be installed into the battery housing 42 , or alternatively, a bottom panel 60 , opposing side panels 62 , and a cover 64 may be assembled around the battery cell 40 and cold plate 66 subassembly to enclose the battery assembly 38 .

[0038] The configuration disclosed herein utilizes a common cold plate 66 to cool the battery cells 40 in both cell layers 48a and 48b, thereby reducing the complexity of the cooling system of the battery assembly 38. This further allows the battery cells 40 to be more compactly packaged in the battery assembly 38 while still providing the necessary cooling of the battery cells 40.

[0039] The term "one" does not indicate a limitation of quantity, but rather indicates the presence of at least one of the referenced items. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0040] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0041] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0042] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery assembly for a vehicle, comprising: a first cell layer, the first cell layer comprising a first plurality of battery cells; a second cell layer comprising a second plurality of battery cells; as well as a cold plate disposed between the first unit layer and the second unit layer, the cold plate comprising a plurality of coolant paths configured to allow a coolant flow to flow therethrough; wherein the first plurality of battery cells contact a first side of the cold plate and the second plurality of battery cells contact a second side of the cold plate opposite the first side to cool the first and second plurality of battery cells via the coolant flow through the cold plate.

2. The battery assembly according to claim 1, wherein: The battery cells each have a first cell end and a second cell end opposite the first cell end, and the second cell end of each battery cell of the first cell layer and the second cell layer contacts the cold plate.

3. The battery assembly according to claim 1, wherein: The second plurality of battery cells are inverted relative to the first plurality of battery cells.

4. The battery assembly of claim 1, further comprising a battery disconnect unit operably connected to one of the plurality of battery cells and cooled by a coolant flow diverted from the cold plate via one of a fluid parallel or series connection.

5. A vehicle comprising: Car body; A propulsion system, the propulsion system is used to drive the movement of the vehicle, the propulsion system includes a battery assembly for powering the propulsion system, the battery assembly includes: a first cell layer, the first cell layer comprising a first plurality of battery cells; a second cell layer comprising a second plurality of battery cells; and a cold plate disposed between the first unit layer and the second unit layer, the cold plate comprising a plurality of coolant paths configured to allow a coolant flow to flow therethrough; wherein the first plurality of battery cells contact a first side of the cold plate and the second plurality of battery cells contact a second side of the cold plate opposite the first side to cool the first and second plurality of battery cells via the coolant flow through the cold plate.

6. The vehicle according to claim 5, wherein: The battery cells each have a first cell end and a second cell end opposite the first cell end, and the second cell end of each battery cell of the first cell layer and the second cell layer contacts the cold plate.

7. The vehicle according to claim 5, wherein: The second plurality of battery cells are inverted relative to the first plurality of battery cells. 8 . The vehicle of claim 5 , further comprising a battery disconnect unit operably connected to one of the plurality of battery cells and cooled via the coolant flow.

9. A method of assembling a battery assembly, comprising: assembling a first plurality of battery cells to a first side of a cold plate, the cold plate comprising a plurality of coolant paths configured to flow a coolant therethrough; as well as assembling a second plurality of battery cells to a second side of the cold plate opposite the first side; wherein the first plurality of battery cells contact a first side of the cold plate and the second plurality of battery cells contact the second side of the cold plate to cool the first and second plurality of battery cells via the coolant flow through the cold plate.

10. The method according to claim 9, wherein: The second plurality of battery cells are inverted relative to the first plurality of battery cells.

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