Thermal management system for rechargeable energy storage system

Abstract

A battery system includes: a first rechargeable energy storage system (RESS) including a first housing; a second RESS including a second housing; and a thermal management system fluidly connected to the first RESS and the second RESS. The thermal management system includes a thermal management fluid source, an inlet manifold including a thermal management fluid inlet in fluid connection with the thermal management fluid source, and an outlet manifold including a thermal management fluid outlet in fluid connection with the thermal management fluid inlet manifold. A first thermal management fluid supply conduit extends through the first RESS and includes a first end connected to the inlet manifold and a second end connected to the first housing. A second thermal management fluid supply conduit extends through the second RESS and includes a first end connected to the inlet manifold and a second end connected to the second housing.

Description

Technical Field

[0001] The present invention relates to the field of rechargeable energy storage systems, and more particularly, to a thermal management system for a rechargeable energy storage system. Background Art

[0002] A battery assembly is formed by a plurality of battery cells arranged in a battery pack. The battery cells include an electrode stack disposed in a housing. The battery cells are charged by an external system and discharged to a load. Various factors, such as manufacturing defects or battery cycling (e.g., charging and discharging) beyond the design limits / capabilities, can lead to a thermal runaway condition that may affect the entire battery assembly. There are various efforts to cool the battery system. Current systems may need to be connected to an external cooling medium. Rapidly reducing the temperature of the battery pack can prevent or stop a thermal runaway condition. Therefore, it is desirable to provide a system for rapidly reducing the temperature of the battery cells in order to prevent and / or stop thermal runaway. Summary of the Invention

[0003] According to a non-limiting example, a battery system includes: a first rechargeable energy storage system (RESS) including a first housing; a second RESS including a second housing; and a thermal management system fluidly connected to the first RESS and the second RESS. The thermal management system includes a thermal management fluid source, an inlet manifold including a thermal management fluid inlet fluidly connected to the thermal management fluid source, and an outlet manifold including a thermal management fluid outlet fluidly connected to the thermal management fluid inlet manifold. A first thermal management fluid supply conduit extends through the first RESS. The first thermal management fluid supply conduit includes a first end connected to the inlet manifold and a second end connected to the first housing. A second thermal management fluid supply conduit extends through the second RESS. The second thermal management fluid supply conduit includes a first end portion connected to the inlet manifold and a second end portion connected to the second housing.

[0004] In addition to one or more of the features described herein, a first inlet valve is disposed in the first thermal management fluid supply conduit, and the first inlet valve selectively creates a first passage that fluidly connects the inlet manifold to the outlet manifold through the first RESS.

[0005] In addition to one or more of the features described herein, a first outlet valve is disposed in the first thermal management fluid supply conduit at the outlet manifold.

[0006] In addition to one or more of the features described herein, the first inlet valve is a normally closed valve and the first outlet valve is a normally open valve.

[0007] In addition to one or more of the features described herein, a second inlet valve is disposed in the second thermal management fluid supply conduit, and the second inlet valve selectively creates a second passage that fluidly connects the inlet manifold to the outlet manifold through the second RESS.

[0008] In addition to one or more features described herein, a second outlet valve is disposed in a second thermal management fluid supply conduit at an outlet manifold.

[0009] In addition to one or more features described herein, the second inlet valve is a normally closed valve and the second outlet valve is a normally open valve.

[0010] In addition to one or more features described herein, a first sensor is mounted in the first RESS and a second sensor is mounted in the second RESS.

[0011] In addition to one or more features described herein, a control system is operably connected to the first sensor, the second sensor, the first inlet valve, and the second inlet valve, and the control system selectively opens the first inlet valve and the second inlet valve based on trigger parameters sensed in the first RESS and the second RESS, respectively.

[0012] In addition to one or more features described herein, the thermal management fluid source includes a thermal management fluid container.

[0013] In addition to one or more features described herein, the thermal management fluid container includes a water container.

[0014] In addition to one or more features described herein, the thermal management fluid source includes a body of water.

[0015] In addition to one or more features described herein, the body of water includes one of a fresh water body and a salt water body.

[0016] In addition to one or more features described herein, the thermal management fluid source includes a water facility.

[0017] According to a non-limiting example, a method of managing temperature in a battery system includes: sensing a first internal temperature in a first rechargeable energy storage system (RESS); sensing a second internal temperature in a second (RESS); detecting a trigger parameter in the first RESS; opening a valve fluidly connecting the first RESS to a thermal management fluid source; and passing thermal management fluid from the thermal management fluid source through a first thermal management fluid supply conduit connected to the thermal management fluid source and through the first RESS.

[0018] In addition to one or more features described herein, the method further includes closing an outlet valve fluidly connected to a second thermal management fluid supply conduit connected to the thermal management fluid source and passing through the second RESS before passing the thermal management fluid through the first thermal management fluid supply conduit.

[0019] In addition to one or more features described herein, the method further includes transferring the thermal management fluid from the first RESS to a discharge device.

[0020] In addition to one or more features described herein, delivering a thermal management fluid to an ejection device includes delivering the thermal management fluid into an outlet manifold that is fluidly connected to each of a first thermal management fluid supply conduit and a second thermal management fluid supply conduit.

[0021] In addition to one or more features described herein, passing a thermal management fluid from a thermal management fluid source through a first thermal management fluid supply conduit includes introducing the thermal management fluid into an inlet manifold that is fluidly connected to the first thermal management fluid supply conduit and the second thermal management fluid supply conduit.

[0022] In addition to one or more features described herein, delivering a thermal management fluid into an inlet manifold includes sucking water from a water body into the inlet manifold.

[0023] When taken in conjunction with the accompanying drawings, the above-described features and advantages of the present disclosure, as well as other features and advantages, will become apparent from the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other features, advantages, and details appear only by way of example in the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1 is a schematic diagram of a rechargeable energy storage system (RESS) including a thermal management system according to a non-limiting example;

[0026] Figure 2 is a schematic diagram of a control system for a thermal management system according to a non-limiting example;

[0027] Figure 3 depicts a container including a battery system having a thermal management system according to a non-limiting example; and

[0028] Figure 4 is a perspective view of a locomotive including a battery system having a thermal management system according to a non-limiting example. DETAILED DESCRIPTION

[0029] 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 drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the term module refers to a processing circuit that may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) executing one or more software or firmware programs, a memory, combinational logic circuitry, and / or other suitable components that provide the described functionality.

[0030] According to a non-limiting example, the battery system is in Figure 1is generally shown at 10. The battery system 10 includes a first rechargeable energy storage system (RESS) 12, a second RESS 14, a third RESS 16, a fourth RESS 18, and a fifth RESS 20. The number and arrangement of the rechargeable energy storage systems can vary and can depend on the energy delivery requirements. For example, the battery system 10 can provide power to a residence, business, factory, etc. The first RESS 12 includes a first housing 26, the second RESS 14 includes a second housing 28, the third RESS 16 includes a third housing 30, the fourth RESS 18 includes a fourth housing 32, and the fifth RESS 20 includes a fifth housing 34. Although shown as being disposed in separate housings, it should be understood that multiple rechargeable energy storage systems can be integrated into a single housing.

[0031] Further according to a non-limiting example, the first RESS 12 includes a first inlet 36 and a first outlet 38. The second RESS 14 includes a second inlet 40 and a second outlet 42. The third RESS 16 includes a third inlet 44 and a third outlet 46. The fourth RESS 18 includes a fourth inlet 48 and a fourth outlet 50, and the fifth RESS 20 includes a fifth inlet 52 and a fifth outlet 54. As will be described in more detail herein, the first inlet 36, the second inlet 40, the third inlet 44, the fourth inlet 48, and the fifth inlet 52 provide a path for a thermal management fluid to selectively enter and cool any of the first RESS 12, the second RESS 14, the third RESS 16, the fourth RESS 18, and the fifth RESS 20, which have battery cells (not shown) that may be experiencing a significant over-temperature condition, such as thermal runaway.

[0032] In a non-limiting example, the battery system 10 includes a thermal management system 60, which serves as a source of the thermal management fluid. In one non-limiting example, the thermal management system 60 provides a dedicated source of the thermal management fluid 62 to the battery system 10. The dedicated source of the thermal management fluid 62 can be located in a dedicated water storage vessel or container 64 that is directly fluid-connected to, for example, a municipal water supply 66. The container 64 can store an easily accessible supply of the thermal management fluid or water.

[0033] Although shown as the container 64, it should be understood that the thermal management system 60 can simply represent a direct connection between the battery system 10 and the municipal water supply 66 without including any intermediate storage. Regardless of the source, the thermal management system 60 provides a continuous pressurized source of the thermal management fluid to the battery system 10, which can mitigate any overheating conditions that may occur.

[0034] In a non - limiting example, the municipal water supply 66 is fluidly connected to the container 64 via a supply conduit 68. The container 64 is filled with a quantity of heat - management fluid, such as water, and serves as a reservoir in the event of a compromise of the municipal water supply 66. A heat - management fluid delivery conduit 72, which may include a pump 74, is connected to the battery system 10. More specifically, the heat - management system 60 includes an inlet manifold 76 that is connected to the heat - management fluid delivery conduit 72 and to each of the first housing 26, second housing 28, third housing 30, fourth housing 32, and fifth housing 34. The heat - management system 60 also includes an outlet manifold 78 that is connected to each of the first housing 26, second housing 28, third housing 30, fourth housing 32, fifth housing 34, and a heat - management fluid outlet leading to a discharge device 80.

[0035] In a non - limiting example, the heat - management system 60 includes a first heat - management fluid supply conduit 83 that extends through the first housing 26 and is fluidly connected to the inlet manifold 76 and the outlet manifold 78. The heat - management system 60 also includes a second heat - management fluid supply conduit 84 that extends through the second housing 28 and is fluidly connected to the inlet manifold 76 and the outlet manifold 78. A third heat - management fluid supply conduit 85 extends through the third housing 30 and is fluidly connected to the inlet manifold 76 and the outlet manifold 78. A fourth heat - management fluid supply conduit 86 extends through the fourth housing 32 and is fluidly connected to the inlet manifold 76 and the outlet manifold 78. A fifth heat - management fluid supply conduit 87 extends through the fifth housing 34 and is fluidly connected to the inlet manifold 76 and the outlet manifold 78.

[0036] In a non - limiting example, the first heat - management fluid supply conduit 83 includes a first end 88 fluidly connected to the inlet manifold 76 and a second end 89 fluidly connected to the first housing 26. The second heat - management fluid supply conduit 84 includes a first end portion 92 fluidly connected to the inlet manifold 76 and a second end portion 93 fluidly connected to the second housing 28. The third heat - management fluid supply conduit 85, the fourth heat - management fluid supply conduit 86, and the fifth heat - management fluid supply conduit 87 are similarly formed.

[0037] In a non - limiting example, a first heat - fluid management fluid outlet conduit 94 is fluidly connected between a first outlet 38 of the first housing 26 and the outlet manifold 78. A second heat - fluid management fluid outlet conduit 96 is fluidly connected between a second outlet 42 of the second housing 28 and the outlet manifold 78. The third outlet 46, the fourth outlet 50, and the fifth outlet 54 are similarly connected to the outlet manifold 78 via separate heat - fluid management fluid outlet conduits (not separately labeled).

[0038] In a non - limiting example, the first thermal management fluid supply conduit 83 includes a first inlet valve 98 in the first thermal management fluid supply conduit 83 disposed between the first end 88 and the first housing 26, and a first outlet valve 99 in the first thermal management fluid outlet conduit 90 disposed between the first outlet 38 of the first housing 26 and the second end 93. A second inlet valve 102 is disposed in the second thermal management fluid supply conduit 84 between the first end 92 and the second housing 28, and a second outlet valve 103 is disposed in the second thermal management fluid outlet conduit 96 between the second outlet 42 of the second housing 28 and the outlet manifold 78. The first inlet valve 98 selectively establishes a first passage for the thermal management fluid to enter the first housing 26. Similarly, the second inlet valve 102 selectively forms a second passage for the thermal management fluid to enter the second housing 28.

[0039] In a similar manner, the third thermal management fluid supply conduit 85 supports a third inlet valve 105, the third thermal management fluid outlet conduit includes a third outlet valve 106, the fourth thermal management fluid supply conduit 86 supports a fourth inlet valve 110, the fourth thermal management fluid outlet conduit includes a fourth outlet valve 111, the fifth thermal management fluid supply conduit 87 supports a fifth inlet valve 114, and the fifth thermal management fluid outlet conduit includes a fifth outlet valve 115. In a non - limiting example, each of the inlet valves 98, 102, 105, 110, and 114 is a normally - closed valve, and each of the outlet valves 99, 103, 106, 111, and 115 is a normally - open valve.

[0040] Now referring to Figure 2 and continuing to refer to Figure 1 , a first sensor 120 is disposed in the first housing 26, a second sensor 121 is disposed in the second housing 28, a third sensor 122 is disposed in the third housing 30, a fourth sensor 123 is disposed in the fourth housing 32, and a fifth sensor 124 is disposed in the fifth housing 34. The first sensor 120, the second sensor 121, the third sensor 122, the fourth sensor 123, and the fifth sensor 124 are arranged to detect a triggering parameter or an abnormal operating condition of a corresponding one of the first RESS 12, the second RESS 14, the third RESS 16, the fourth RESS 18, and the fifth RESS 20. The triggering parameter can be based on temperature values, voltage values, current values, gas values, pressure values, infrared values, light values, audio values, and / or other suitable measured values. The trigger value can represent an absolute value, a rate - of - change value, and / or an integral value. For example, the sensor can detect an out - of - range temperature, an abnormal voltage, etc., and these abnormal voltages indicate abnormal operating conditions such as over - temperature conditions that may lead to a thermal runaway condition.

[0041] In a non-limiting example, the control system 130 is connected to the battery system 10 and the thermal management system 60. The control system 130 includes a central processing unit (CPU) 133, a non-volatile memory 135, a valve control module 139, and a thermal management control module 142. The control system 130 receives inputs from each of the first sensor 120, the second sensor 121, the third sensor 122, the fourth sensor 123, and the fifth sensor 124. In a non-limiting example, the first sensor 120 provides a first internal temperature value, the second sensor 121 provides a second internal temperature value, the third sensor 122 provides a third internal temperature value, the fourth sensor 124 provides a fourth internal temperature value, and the fifth sensor 124 provides a fifth internal temperature value. The thermal management control module 142 evaluates the internal temperature values to determine whether the battery system 10 is experiencing a thermal response that exceeds the value stored in the non-volatile memory 135. If the thermal response indicates a potential thermal runaway condition, the thermal management control module 142 takes remedial measures.

[0042] In a non-limiting example, if the thermal management control module 142 detects an over-temperature condition, for example, in the first RESS 12, the valve control module 139 signals the second outlet valve 103, the third outlet valve 106, the fourth outlet valve 111, and the fifth outlet valve 115 to close. In this way, the second housing 28, the third housing 30, the fourth housing 32, and the fifth housing 34 are isolated from the outlet manifold 78. At this time, the valve control module 139 opens the first inlet valve 98, allowing the thermal management fluid to flow from the inlet manifold 76 through the first housing 26 in order to reduce the temperature and prevent the over-temperature condition from getting out of control. The direct access to the thermal management fluid ensures that the over-temperature condition can be quickly alleviated.

[0043] In a non-limiting example, the second end 89 of the first thermal management fluid supply conduit 83 and the second end 93 of the second thermal management fluid supply conduit 84 represent RESS interfaces (not shown separately) that open when the thermal management fluid passes through the first inlet valve 98 and / or the second inlet valve 102 (e.g., by rupturing a burst diaphragm, opening a check valve, etc.). The use of a burst diaphragm, check valve, etc. ensures that gases that may be generated in, for example, the first RESS 12 and / or the second RESS 14 do not enter the thermal fluid management system 60 via the inlet manifold 76.

[0044] Reference Figure 3, the battery system 10 and the thermal management system 60 can be integrated into a container, such as a boat 154 located in a body of water 156. The body of water 156 can be a fresh water body or a salt water body. The boat 154 includes a waterline 160. In a non-limiting example, the inlet manifold 76 includes an inlet 165 disposed below the waterline 160. In this way, in the event of an over-temperature condition in the battery system 10, the thermal management control module 142 can operate the pump 74 to draw the thermal management fluid directly from the body of water 156. The direct access to the thermal management fluid (e.g., water) ensures that the over-temperature condition can be quickly alleviated, allowing the battery system 10 to continue operating so that the boat 154 can seek a nearby port. The fluid flowing into the battery system 10 will pass through the outlet so that the boat 154 does not bear unnecessary ballast.

[0045] In Figure 4 , the battery system 10 and the thermal management system 60 can be integrated into a locomotive 170. The locomotive 170 can use the battery system 10 as the primary power source or the secondary power source. Regardless of the application, the thermal management system 60 includes a container 64 that stores a certain amount of thermal management fluid. In this way, in the event of an over-temperature condition in the battery system 10, the thermal management control module 142 can operate the pump 74 to draw the thermal management fluid directly from the container 64 and allow a ready supply of pressurized thermal management fluid to pass through the affected RESS. The direct access to the thermal management fluid (e.g., water) ensures that the over-temperature condition can be quickly alleviated, allowing the battery system 10 to continue operating so that the locomotive 170 can seek service. In addition to supplying the thermal management fluid to the battery system 10, the outlet manifold can include additional ports (not shown) to which emergency service personnel can connect if needed.

[0046] 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 "in one aspect" mean that the particular elements (e.g., features, structures, steps, or characteristics) described in connection with that aspect are 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 can be combined in any suitable manner in the various aspects.

[0047] 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.

[0048] Unless stated to the contrary herein, all test standards are the latest valid standards as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0049] Unless otherwise defined, 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.

[0050] Although the foregoing disclosure has been described with reference to exemplary embodiments, those of ordinary skill in the art will understand 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 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 system comprising: a first rechargeable energy storage system (RESS) comprising a first housing; a second RESS comprising a second housing; and A thermal management system fluidly connected to the first RESS and the second RESS, the thermal management system comprising: thermal management fluid source; an inlet manifold fluidly connected to a source of thermal management fluid; an outlet manifold including a thermal management fluid outlet fluidly connected to the thermal management fluid inlet manifold; a first thermal management fluid supply conduit extending through the first RESS, the first thermal management fluid supply conduit including a first end connected to the inlet manifold and a second end connected to the first housing; and A second thermal management fluid supply conduit extends through the second RESS, the second thermal management fluid supply conduit including a first end connected to the inlet manifold and a second end connected to the second housing.

2. The battery system of claim 1 , further comprising a first inlet valve disposed in the first thermal management fluid supply conduit, the first inlet valve selectively creating a first passage fluidly connecting the inlet manifold with the outlet manifold through the first RESS. 3 . The battery system of claim 2 , further comprising a first outlet valve disposed in a first thermal management fluid supply conduit at the outlet manifold.

4. The battery system according to claim 3, wherein: The first inlet valve is a normally closed valve, and the first outlet valve is a normally open valve.

5. The battery system of claim 3, further comprising a second inlet valve disposed in the second thermal management fluid supply conduit, the second inlet valve selectively creating a second passage fluidly connecting the inlet manifold with the outlet manifold through the second RESS.

6. The battery system of claim 5, further comprising a second outlet valve disposed in a second thermal management fluid supply conduit at the outlet manifold, wherein: The second inlet valve is a normally closed valve, and the second outlet valve is a normally open valve. 7 . The battery system of claim 6 , further comprising a first sensor installed in the first RESS and a second sensor installed in the second RESS.

8. The battery system according to claim 7 further includes a control system operably connected to the first sensor, the second sensor, the first inlet valve and the second inlet valve, the control system selectively opening the first inlet valve and the second inlet valve based on trigger parameters sensed in the first RESS and the second RESS, respectively.

9. The battery system according to claim 1, wherein: The thermal-management fluid source includes a thermal-management fluid container.

10. A method of managing temperature in a battery system, the method comprising: sensing a first internal temperature in a first rechargeable energy storage system (RESS); sensing a second internal temperature in a second (RESS); detecting a trigger parameter in a first RESS; opening a valve fluidly connecting the first RESS to a source of thermal management fluid; as well as A thermal-management fluid is passed from a thermal-management fluid source through a first thermal-management fluid supply conduit connected to the thermal-management fluid source and through a first RESS.

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