Rechargeable energy storage system including cold plate with integrated vent

Abstract

A battery assembly includes a housing having a bottom wall and a plurality of side walls that collectively define an interior region. A plurality of battery cells are arranged in the interior region. The heat exchange member is disposed between the bottom wall and the plurality of battery cells. The heat exchange member includes a plurality of coolant fluid channels conveying coolant fluid in heat exchange contact with the plurality of battery cells and a plurality of exhaust channels fluidly connected to the plurality of battery cells.

Description

Technical Field

[0001] The present invention relates to a vehicle, and more particularly, to a rechargeable energy storage system (RESS) including a cold plate with an integrated vent. Background Art

[0002] Many newer vehicles are being manufactured with electric propulsion systems. Electric propulsion systems, whether fully electric or hybrid electric, rely on electric motors powered by energy stored in a rechargeable energy storage system (RESS) or battery. During operation, the battery generates heat. The heat reduces battery efficiency. To reduce the heat generated by the battery, many vehicles include a cooling system that circulates a coolant fluid in thermal contact with the battery.

[0003] In some cases, the cooling system includes a plate disposed within the battery housing. The battery cells rest on the plate. The coolant fluid passes through the plate in a heat exchange relationship with the battery cells. In addition to cooling, the battery assembly also includes a ventilation system that vents gases from the battery housing. Gases generated within the battery cells are directed through conduits that exit the housing. The battery cells, cooling, ventilation, and power control systems occupy space within the battery assembly. The requirement to add additional systems in a vehicle drives the need to reduce the footprint of components. Accordingly, it is desirable to integrate components in order to create space that can accommodate additional systems. Summary of the Invention

[0004] According to a non-limiting example, a battery assembly includes a housing having a bottom wall and a plurality of side walls that together define an interior region. A plurality of battery cells are disposed within the interior region. A heat exchange member is disposed between the bottom wall and the plurality of battery cells. The heat exchange member includes a plurality of coolant fluid channels and a plurality of exhaust channels, the coolant fluid channels conveying a coolant fluid in heat exchange contact with the plurality of battery cells, and the exhaust channels being fluidly connected to the plurality of battery cells.

[0005] In addition to one or more of the features described herein, each of the plurality of coolant fluid channels includes a first end, a second end, and an intermediate portion, and the plurality of coolant fluid channels extend along an axis of the heat exchange member.

[0006] In addition to one or more of the features described herein, each of the plurality of exhaust channels includes a first end portion, a second end portion, and an intermediate portion, and the plurality of exhaust channels extend along an axis of the heat exchange member.

[0007] In addition to one or more of the features described herein, each of the plurality of exhaust channels is disposed between adjacent channels of the plurality of coolant fluid channels.

[0008] In addition to one or more features described herein, a dam member extends substantially perpendicular to a plurality of coolant fluid channels and a plurality of exhaust channels through a heat exchange member. The dam member includes a first end segment, a second end segment, and an intermediate segment. The intermediate segment closes a second end of each of the plurality of exhaust channels.

[0009] In addition to one or more features described herein, the dam member includes an internal flow channel fluidly connecting a second end of each of the plurality of coolant fluid channels.

[0010] In addition to one or more features described herein, a coolant fluid inlet is fluidly connected to one of the plurality of coolant fluid channels and a first end of the dam member, and a coolant fluid outlet is fluidly connected to another of the plurality of coolant fluid channels and a second end of the dam member.

[0011] In addition to one or more features described herein, an exhaust collection member extends substantially perpendicular to the plurality of coolant fluid channels and the plurality of exhaust channels through the heat exchange member. The exhaust collection member fluidly connects a first end of each of the plurality of exhaust channels to a sensor housing.

[0012] In addition to one or more features described herein, the exhaust collection member includes an exhaust collection channel that includes a first channel portion extending through the heat exchange member, a second channel portion extending along an axis, and a third channel portion extending through the heat exchange member. The third channel portion includes the sensor housing.

[0013] In addition to one or more features described herein, the exhaust collection member includes an internal coolant fluid channel fluidly connecting each of the plurality of coolant fluid channels.

[0014] By way of non-limiting example, a vehicle includes a body, a plurality of wheels connected to the body, an electric drive unit supported in the body and operably connected to at least one of the plurality of wheels, and a battery assembly operably connected to the electric drive unit. The battery assembly includes a housing having a bottom wall and a plurality of side walls that together define an internal region. A plurality of battery cells are arranged in the internal region. A heat exchange member is arranged between the bottom wall and the plurality of battery cells. The heat exchange member includes a plurality of coolant fluid channels and a plurality of exhaust channels. The coolant fluid channels convey a coolant fluid in thermal exchange contact with the plurality of battery cells, and the exhaust channels are fluidly connected to the plurality of battery cells.

[0015] In addition to one or more features described herein, each of the plurality of coolant fluid channels includes a first end, a second end, and an intermediate portion. The plurality of coolant fluid channels extend along an axis of the heat exchange member.

[0016] In addition to one or more features described herein, each of the plurality of exhaust passages includes a first end, a second end, and an intermediate portion, and the plurality of exhaust passages extend along an axis of the heat exchange member.

[0017] In addition to one or more features described herein, each of the plurality of exhaust passages is disposed between adjacent ones of the plurality of coolant fluid passages.

[0018] In addition to one or more features described herein, a dam member extends through the heat exchange member substantially perpendicular to the plurality of coolant fluid passages and the plurality of exhaust passages, the dam member including a first end segment, a second end segment, and an intermediate segment, the intermediate segment closing the second end of each of the plurality of exhaust passages.

[0019] In addition to one or more features described herein, the dam member includes an internal flow passage fluidly connecting the second end of each of the plurality of coolant fluid passages.

[0020] In addition to one or more features described herein, a coolant fluid inlet is fluidly connected to one of the plurality of coolant fluid passages and the first end of the dam member, and a coolant fluid outlet is fluidly connected to another of the plurality of coolant fluid passages and the second end of the dam member.

[0021] In addition to one or more features described herein, an exhaust collection member extends through the heat exchange member substantially perpendicular to the plurality of coolant fluid passages and the plurality of exhaust passages, the exhaust collection member fluidly connecting the first end of each of the plurality of exhaust passages to a sensor housing.

[0022] In addition to one or more features described herein, the exhaust collection member includes an exhaust collection passage that includes a first passage portion extending through the heat exchange member, a second passage portion extending along the axis, and a third passage portion extending through the heat exchange member, the third passage portion including the sensor housing.

[0023] In addition to one or more features described herein, the exhaust collection member includes an internal coolant fluid passage that fluidly connects each of the plurality of coolant fluid passages.

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

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

[0026] Figure 1A left side view of a vehicle including a rechargeable energy storage system (RESS) according to a non - limiting example, the rechargeable energy storage system having a cold plate including an integrated vent;

[0027] Figure 2 A partial perspective view of a battery assembly having a cold plate including an integrated vent according to a non - limiting example;

[0028] Figure 3 Is according to a non - limiting example including Figure 2 A top view of a cold plate with an integrated vent;

[0029] Figure 4 A cross - sectional perspective view of a cold plate including an integrated vent supporting battery cells according to a non - limiting example;

[0030] Figure 5 A perspective rear view showing a dam member mounted to a cold plate according to a non - limiting example;

[0031] Figure 6 A perspective front view showing an exhaust collection member mounted to a cold plate according to a non - limiting example;

[0032] Figure 7 An upper - right perspective view of a cold plate and a dam member according to a non - limiting example; and

[0033] Figure 8 A top view of an exhaust collection member according to a non - limiting example. DETAILED DESCRIPTION

[0034] 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 in all the figures, corresponding reference numerals represent the same or corresponding components and features.

[0035] According to a non - limiting example, a vehicle is generally designated by 10 in Figure 1 Vehicle 10 includes a body 12 supported on a plurality of wheels 16. Body 12 partially defines a passenger compartment 20 having a seat 23 located behind a dashboard 26. A steering controller 30 is disposed between seat 23 and dashboard 26. Steering controller 30 is operated to control the orientation of a selected one of the plurality of wheels 16. Vehicle 10 includes an electric drive unit 34 that provides power to one or more of the plurality of wheels 16.

[0036] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed in body 12 and provides power to electric drive unit 34. In other arrangements, a fuel cell (not shown) may be used to provide power to electric drive unit 34. In this regard, it should be understood that the positions of electric drive unit 34 and battery assembly 38 may vary. AsFigure 2 As shown, the battery assembly 38 includes a housing 50 having a bottom wall 52 and a plurality of side walls 54 that together define an interior region 58. The plurality of side walls 54 includes a first side wall 60, a second side wall 61, a third side wall 62, and a fourth side wall 63. A plurality of battery cells 68 are disposed in the interior region 58 of the housing 50.

[0037] In a non-limiting example, a heat exchange member or cold plate 80 supports the plurality of battery cells 68 on the base 52. Refer Figure 3 and 4 , the cold plate 80 includes a first surface 86 and a second surface 88 opposite the first surface 86. The first surface 86 and the second surface 88 are defined by a first edge 90, a second edge 92, a first side edge 94, and a second side edge 96. An axis “A” of the cold plate 80 extends between the first edge 90 and the second edge 92.

[0038] In a non-limiting example, the cold plate 80 includes a plurality of coolant fluid channels, one of which is designated 102, that extend between the first surface 86 and the second surface 88 and are generally parallel to the axis “A”. The plurality of coolant fluid channels 102 includes a coolant fluid inlet 104 disposed adjacent the first edge 90 at the first side edge 94 and a coolant fluid outlet 106 disposed adjacent the first edge 90 at the second side edge 96. The specific location of each of the coolant fluid inlet 104 and the coolant fluid outlet 106 can vary. Each of the plurality of coolant fluid channels 102 defines a closed conduit that carries a heat-absorbing fluid in heat exchange relation with the plurality of battery cells 68. The coolant fluid channel 102 includes a first end 110 at the first edge 90, a second end 112 at the second edge 92, and an intermediate portion 114 extending between the first end 110 and the second end 112. In the illustrated exemplary embodiment, the coolant fluid channels 102 are spaced apart from each other.

[0039] In a non-limiting example, in addition to the coolant fluid channels 102, the cold plate 80 includes a plurality of gas discharge channels 120 that extend between the first edge 90 and the second edge 92 and are generally parallel to the axis “A”. The gas discharge channels 120 take the form of grooves formed in the first surface 86. In a non-limiting example, each gas discharge channel 120 includes a first end portion 130 near the first edge 90, a second end portion 132 near the second edge 92, and an intermediate portion 134 extending between the first end portion 130 and the second end portion 132. In a non-limiting example, the second end portion 130 is closed by a dam member 140.

[0040] In a non-limiting example, as Figure 3 and Figure 5As shown, the dam member 140 extends across a first surface 86 between a first side edge 94 and a second side edge 96 at a second edge 92. The dam member 140 includes a first end segment 144 at the first side edge 94, a second end segment 146 at the second side edge 96, and an intermediate segment 148 extending between the first end segment 144 and the second end segment 146. An internal flow channel 150 fluidly connects with each of a plurality of coolant fluid channels 102 at a second end 112 and passes through the intermediate segment 148. The internal flow channel 150 facilitates the circulation of a coolant fluid such as water through the coolant fluid channels 102 between a coolant fluid inlet 104 and a coolant fluid outlet 106.

[0041] In a non-limiting example, the dam member 140 further includes a plurality of dam elements 155 that enclose a second end 132 of each of a plurality of gas discharge channels 120. In this way, gas that can be discharged from one or more of the plurality of battery cells 68 is prevented from discharging at the second end 132 and is thus forced to flow toward a first end 130 where the gas can be collected and sampled.

[0042] In a non-limiting example, as Figure 3 、 6 、7, and 8 show, the cold plate 80 includes an exhaust gas collection member 160 disposed across a first edge 90 on the first surface 86. The exhaust gas collection member 160 includes a first edge portion 164 disposed at the first side edge 94 and a second edge portion 166 disposed at the second side edge 96. The exhaust gas collection member 160 includes an internal coolant fluid channel 168 fluidly connected with each of the plurality of coolant fluid channels 102 and an exhaust gas collection channel 170 extending between the first edge portion 164 and the second edge portion 166. The exhaust gas collection channel 170 includes a first channel portion 172 that includes a plurality of gas inlets 174 fluidly connected with each of the plurality of exhaust channels 120. The first channel portion 172 extends along the first edge 90 substantially perpendicular to an axis “A”.

[0043] In Figure 8In the non-limiting example shown, the second channel portion 176 extends from the first channel portion 172 adjacent to the first side edge 94. The second channel portion 176 extends substantially parallel to the axis "A". The exhaust gas collection channel 169 further includes a third channel portion 178, which is fluidly connected to the second exhaust channel portion 172 and extends therefrom to the second side edge 96. The third exhaust channel portion 178 extends substantially perpendicular to the axis "A". The sensor housing or gas collection chamber 182 is fluidly connected to the third channel portion 178 at the second edge 92. The sensor housing 182 may support a sensor (not shown) that samples the gas passing through the plurality of battery cells 68. The geometry of the exhaust gas collection channel 170 ensures that the gas passing through the plurality of exhaust channels 120 has an opportunity to cool before being sampled.

[0044] The terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The term "or" means "and / or" unless the context clearly dictates otherwise. References throughout the specification to "one aspect" mean that a particular element (e.g., a feature, structure, step, or property) described in connection with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. Additionally, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0045] 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.

[0046] Unless stated to the contrary herein, all test standards are the latest valid standards as of the filing date of the present application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0047] Unless otherwise defined, the 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 pertains.

[0048] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made and equivalents may be substituted for its elements without departing from its scope. Additionally, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Accordingly, it is intended that the disclosure not be limited to the particular embodiments disclosed, but that it will include all embodiments falling within its scope.

Claims

1. A battery assembly comprising: a housing including a bottom wall and a plurality of side walls that together define an interior region; a plurality of battery cells disposed in the interior region; as well as A heat exchange member is disposed between the bottom wall and the plurality of battery cells, the heat exchange member including a plurality of coolant fluid channels conveying coolant fluid in heat exchange contact with the plurality of battery cells and a plurality of exhaust channels fluidly connected to the plurality of battery cells.

2. The battery assembly according to claim 1, wherein: Each of the plurality of coolant fluid channels includes a first end, a second end, and a middle portion, and the plurality of coolant fluid channels extend along an axis of the heat exchange member.

3. The battery assembly according to claim 2, wherein: Each of the plurality of exhaust passages includes a first end portion, a second end portion, and a middle portion, and the plurality of exhaust passages extend along an axis of the heat exchange member.

4. The battery assembly according to claim 3, wherein: Each of the plurality of exhaust passages is disposed between adjacent passages of the plurality of coolant fluid passages.

5. The battery assembly according to claim 3 further includes a dam member extending through the heat exchange member substantially perpendicular to the plurality of coolant fluid channels and the plurality of exhaust channels, the dam member including a first end section, a second end section and a middle section, the middle section closing the second end of each of the plurality of exhaust channels.

6. The battery assembly according to claim 5, wherein: The dam member includes an internal flow channel fluidly connecting the second end of each of the plurality of coolant fluid channels.

7. The battery assembly of claim 5, further comprising a coolant fluid inlet fluidly connected to one of the plurality of coolant fluid channels and the first end of the dam member, and a coolant fluid outlet fluidly connected to another one of the plurality of coolant fluid channels and the second end of the dam member.

8. The battery assembly of claim 5, further comprising an exhaust collection member extending through the heat exchange member substantially perpendicular to the plurality of coolant fluid channels and the plurality of exhaust channels, the exhaust collection member fluidly connecting a first end of each of the plurality of exhaust channels to a sensor housing.

9. The battery assembly according to claim 8, wherein: The exhaust gas collecting member includes an exhaust gas collecting channel including a first channel portion extending through the heat exchange member, a second channel portion extending along the axis, and a third channel portion extending through the heat exchange member, the third channel portion including a sensor housing.

10. A vehicle comprising: Car body; a plurality of wheels connected to the vehicle body; an electric drive unit supported in the vehicle body and operatively connected to at least one of the plurality of wheels; as well as A battery assembly as previously described is operably connected to the electric drive unit.

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