Battery pack discharge assembly

Abstract

A battery pack drain assembly includes a drain housing having an annular outer wall and an annular inner wall, an annular passage defined between the outer wall and the inner wall, and a main drain valve disposed at least partially within the inner wall. The main discharge valve is configured to open when liquid in the discharge housing reaches the top of the inner wall.

Description

Technical Field

[0001] The present invention relates to a vehicle, and more particularly to a discharge assembly for a vehicle battery pack. Background Art

[0002] The battery pack used in a vehicle may include a discharge valve that allows liquid to be discharged from the battery. There is a need for an intelligent and efficient discharge valve. Summary of the Invention

[0003] In one exemplary embodiment, a battery pack discharge assembly includes a discharge housing having an annular outer wall and an annular inner wall. An annular channel is defined between the outer wall and the inner wall. A main discharge valve is disposed at least partially within the inner wall. The main discharge valve is configured to open when the liquid in the discharge housing reaches the upper portion of the inner wall.

[0004] In addition to one or more of the features described herein, the battery pack discharge assembly includes a shoulder extending from the upper portion of the inner wall, wherein the shoulder and the inner wall define a valve seat.

[0005] In addition to one or more of the features described herein, an opening is formed in the shoulder, and the main discharge valve passes through the opening.

[0006] In addition to one or more of the features described herein, the battery pack discharge assembly includes a second discharge valve disposed on the outer wall.

[0007] In addition to one or more of the features described herein, the second discharge valve is a check valve.

[0008] In addition to one or more of the features described herein, the second discharge valve is a one-way valve.

[0009] In addition to one or more of the features described herein, the second discharge valve is a flap valve.

[0010] In addition to one or more of the features described herein, the second discharge valve is formed by a membrane that allows water vapor to pass through while preventing liquid from passing through when the second discharge valve is closed.

[0011] In addition to one or more of the features described herein, the discharge housing includes a lower housing and an upper housing, the lower housing includes an inner wall and an outer wall, and the upper housing is mounted on the lower housing to form a closed space therein.

[0012] In addition to one or more of the features described herein, the battery pack discharge assembly includes a second discharge valve disposed on the outer wall, wherein the upper housing includes a second discharge groove located above the second discharge valve.

[0013] In addition to one or more of the features described herein, the upper housing is mounted on the lower housing by fasteners.

[0014] In addition to one or more features described herein, the upper housing is removably mounted to the lower housing by fasteners.

[0015] In addition to one or more features described herein, the inner wall is higher than the outer wall.

[0016] In addition to one or more features described herein, the main discharge valve includes a sensor that senses when liquid reaches the top of the inner wall.

[0017] In another exemplary embodiment, a battery pack assembly includes a battery pack housing that includes a battery pack housing floor. A plurality of battery cells are disposed within the battery pack housing, wherein a battery pack discharge assembly is embedded in the battery pack housing floor. The battery pack discharge assembly includes a discharge housing that includes an annular outer wall and an annular inner wall. An annular channel is defined between the outer wall and the inner wall. The main discharge valve is at least partially disposed within the inner wall. The main discharge valve is configured to open when liquid in the discharge housing reaches the upper portion of the inner wall.

[0018] In addition to one or more features described herein, the battery pack discharge assembly includes a second discharge valve disposed on the outer wall.

[0019] In addition to one or more features described herein, the second discharge valve is a check valve.

[0020] In addition to one or more features described herein, the upper surface of the second discharge valve is flush with or lower than the battery pack housing floor.

[0021] In addition to one or more features described herein, the battery pack discharge assembly is disposed at the lowest portion of the battery pack housing floor.

[0022] In yet another exemplary embodiment, a vehicle includes a battery pack assembly that includes a battery pack housing that includes a battery pack housing floor. A plurality of battery cells are disposed within the battery pack housing. The vehicle includes a cooling system for cooling the battery cells. A battery pack discharge assembly is embedded in the battery pack housing floor. The battery pack discharge assembly includes a lower housing that includes an annular outer wall, an annular inner wall, and a shoulder extending inwardly from the top of the inner wall. An upper housing is mounted on the lower housing to form an enclosed space therebetween. An annular channel is defined between the outer wall and the inner wall. The main discharge valve is disposed through an opening in the shoulder and is at least partially located within the inner wall. A second discharge valve, which is a one-way valve, is disposed on the outer wall. The main discharge valve is configured to open when liquid in the discharge housing reaches the shoulder.

[0023] The above-described features and advantages of the present disclosure, as well as other features and advantages, will become apparent when the following detailed description is read in conjunction with the accompanying drawings. 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, wherein:

[0025] Figure 1 is a left side view of a vehicle including a battery pack assembly having a battery pack discharge assembly according to a non - limiting example;

[0026] Figure 2 is a schematic view of a battery pack assembly including a battery pack discharge assembly according to a non - limiting example;

[0027] Figure 3 is a top perspective view of a battery pack discharge assembly according to a non - limiting example;

[0028] Figure 4 is Figure 3 a cross - sectional view of the battery pack discharge assembly shown in at 4 - 4;

[0029] Figure 5 is a top perspective view of a lower housing and a main discharge valve according to a non - limiting example;

[0030] Figure 6 is Figure 5 a cross - sectional view of the lower housing and the main discharge valve shown in at 6 - 6; and

[0031] Figure 7 is a bottom view of an upper housing and a second discharge valve according to a non - limiting example. 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 in all the figures, corresponding reference numerals indicate like or corresponding parts and features.

[0033] Figure 1 A vehicle 10 is shown in according to a non - limiting example. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. One or more of the plurality of wheels 16 are steerable. The body 12 partially defines a passenger compartment 20 having a seat 23 located behind a dashboard 26. A steering controller 30 is disposed between the seat 23 and the dashboard 26. The steering controller 30 is operated to control the direction of the steering wheels 16.

[0034] The vehicle 10 includes an electric motor 34 connected to a transmission 36, and the transmission 36 provides power to one or more of the plurality of wheels 16. A rechargeable energy storage system 38 is disposed in the body 12 and supplies power to the electric motor 34. Although in Figure 1The specific locations of the electric motor 34, the transmission 36, and the rechargeable energy storage system 38 are shown, but these locations are merely exemplary and not restrictive, and the locations of these structures can vary.

[0035] Figure 2 A battery pack assembly 100 is shown according to a non - restrictive example. According to one or more embodiments, the battery pack assembly 100 can be Figure 1 a part of the rechargeable energy storage system 38 shown. The battery pack assembly 100 can include a battery module 110 having a plurality of battery cells 115. According to one or more embodiments, the battery module 110 is disposed within a battery pack housing 120. The battery module 110 and the battery pack housing 120 can be considered together as the battery pack assembly. Although Figure 2 a single battery module 110 within the battery pack housing 120 is shown, a plurality of battery modules 110 can be disposed within the battery pack housing 120. The battery cells 115 can be pouch cells, prismatic cells, cylindrical cells, or other battery cells known in the art. According to one or more embodiments, the battery pack assembly 100 includes a cooling system 130 for dissipating heat from the battery module 110.

[0036] According to one or more embodiments, the battery pack housing 120 can include a battery pack housing bottom plate 121. According to one or more embodiments, a battery pack discharge assembly 200 is disposed on the battery pack housing bottom plate 121. The battery pack discharge assembly 200 is located at the lowest part of the battery pack housing bottom plate 121 such that liquid can flow by gravity towards the battery pack discharge assembly 200.

[0037] Figure 3 A battery pack discharge assembly 200 is shown according to one or more embodiments, Figure 4 and a cross - sectional view of the battery pack discharge assembly 200 taken at 4 - 4 in Figure 3 is shown. Figure 5 A lower housing 220 and a main discharge valve 240 are shown according to one or more embodiments, Figure 6 and a cross - sectional view of the lower housing 220 and the main discharge valve 240 taken at 6 - 6 in Figure 5 is shown. Figure 7 An upper housing 210 and a second discharge valve 230 are shown according to one or more embodiments.

[0038] According to one or more embodiments, the battery pack discharge assembly 200 includes an upper housing 210, a lower housing 220, a plurality of second discharge valves 230, a main discharge valve 240, and a plurality of fasteners 250. Although the battery pack discharge assembly 200 is shown as having four second discharge valves 230 and four fasteners 250, the present invention is not limited thereto. For example, there may be one second discharge valve 230 and / or one fastener 250, or any number of second discharge valves 230 and / or fasteners 250.

[0039] According to one or more embodiments, the upper housing 210 may include a body 211 configured as a circular dome. According to one or more embodiments, the upper housing 210 may have another shape, such as a cylindrical or rectangular box shape. A plurality of fastener grooves 212 may be formed in the periphery of the body 211, which are configured to allow the fasteners 250 to pass therethrough. According to one or more embodiments, the fastener grooves 212 may include a curved surface. According to one or more embodiments, each fastener groove 212 may include an opening for a portion of the fastener 250 to pass through and an abutting surface for the head of the fastener 250 to generate a downward force toward the lower housing 220 on the upper housing 210. A plurality of second discharge grooves 213 may be formed in the periphery of the body 211. Each second discharge groove 213 may include a curved surface. According to one or more embodiments, the fastener grooves 212 may be circumferentially offset from the second discharge grooves 213. When the second discharge valve 230 is closed, the bottom surface 214 of each second discharge groove 213 may abut the upper surface of the interior 233 of the second discharge valve 230 to form a seal. An internal dome structure 215 may be formed in the central portion of the body 211 of the upper housing 210.

[0040] According to one or more embodiments, the lower housing 220 may include an inner wall 221, an outer wall 223, and a bottom plate 224 extending between the inner wall 221 and the outer wall 223. The inner wall 221 and the outer wall 223 may be annular structures that continuously extend around the central axis A of the lower housing 220. The inner wall 221, the bottom plate 224, and the outer wall 223 may define an annular channel 300 in the space between the inner wall 221 and the outer wall 223. A valve seat 229 may be formed in the central portion of the lower housing 220. The valve seat 229 includes the inner wall 221 and a shoulder 222 extending from its upper portion. The shoulder 222 extends radially inwardly toward the central axis A of the lower housing 220. The shoulder 222 may include a main discharge valve opening 225 located in its radially central portion, and the main discharge valve 240 may be received in the opening. According to one or more embodiments, the inner wall 221 may be higher than the outer wall 223. The outer wall 223 may include a plurality of second discharge valve attachment surfaces 226 that are recessed downward from the rest of the outer wall 223. The bottom surface of the exterior 231 of the second discharge valve 230 may be attached to each of the second discharge valve attachment surfaces 226 by an adhesive, bonding, or any other attachment method. Alternatively, the second discharge valve 230 may be integrally formed with the lower housing 220. A plurality of circumferentially offset attachment posts 227 may project upward from the outer wall 223. Each of the plurality of attachment posts 227 may have a hole 228 formed therein. A portion of a fastener 250 may be inserted into the hole 228. For example, if the fastener 250 is a screw, the inner surface of the hole 228 may be threaded, and the threaded portion of the screw may be inserted into the hole 228 to secure the screw within the hole 228. The upper housing 210 may be mounted on the lower housing 220 to form an enclosed space therein, and the fastener 250 secures the upper housing 210 to the lower housing 220.

[0041] According to one or more embodiments, the battery pack discharge assembly 200 may be at least partially embedded in the battery pack housing bottom plate 121 of the battery pack housing 120, as Figure 2 shown. According to one or more embodiments, the lower housing 220 is partially embedded in the battery pack housing bottom plate 121 such that the top surface of the second discharge valve 230 may be flush with or lower than the surrounding battery pack housing bottom plate 121. Accordingly, the liquid on the battery pack housing bottom plate 121 may flow by gravity to the battery pack discharge assembly 200. The upper housing 210 may be mounted on the lower housing 220 to together form a discharge housing.

[0042] The second discharge valve 230 may be a check valve that opens to allow fluid to flow into the annular channel 300 when the liquid (such as water) is outside the battery pack discharge assembly 200. According to one or more embodiments, the second discharge valve 230 may be a one-way valve. The second discharge valve 230 may be, for example, a flap valve, as Figure 3 , 4As shown in FIGS. 6 and 7. According to one or more embodiments, the second discharge valve 230 may be a silicone baffle valve. According to one or more embodiments, each second discharge valve 230 may be formed of a membrane that, when closed, still allows water vapor to pass through while preventing liquid from passing through. Each second discharge valve 230 may include a body 232 that extends between an exterior 231 that may be attached to the second discharge valve attachment surface 226 and an interior 233 that may abut the bottom surface 214 of the second discharge groove 213, and the bottom surface 214 serves as a valve seat. As Figure 4 shown, when liquid reaches the top of the body 232 to open the second discharge valve 230, the body 232 of the second discharge valve 230 may deform downward. Although the second discharge valve 230 is shown as a baffle valve, the second discharge valve 230 may alternatively be an umbrella valve, a mushroom valve, a butterfly check valve, a ball check valve, a diaphragm check valve, a lift check valve, a swing check valve, a straight-through check valve, a duckbill valve, or any other check valve.

[0043] The main discharge valve 240 is disposed within the main discharge valve opening 225. The main discharge valve 240 may include a body 241 and a sealing surface 243 that, when the main discharge valve 240 is closed, abuts the lower surface of the shoulder 222 to form a seal. The presence of liquid above the shoulder 222 opens the main discharge valve 240 to allow liquid to drain from the battery pack discharge assembly 200. The main discharge valve 240 may include a sensor that senses the presence of liquid above the shoulder 222 to open the main discharge valve 240 and closes the main discharge valve 240 when the sensor no longer senses the presence of liquid. The main discharge valve 240 may be an absorption discharge valve, or any other valve known in the art capable of discharging liquid from the battery pack discharge assembly 200.

[0044] According to one or more embodiments, a plurality of fasteners 250 fasten the upper housing 210 to the lower housing 220. The fasteners 250 may be screws that pass through the fastener grooves 212 of the upper housing 210 into the holes 228 of the attachment posts 227 of the lower housing 220. The fasteners 250 may be removable such that the upper housing 210 may be removed from the lower housing 220 to clear liquid, dust, or debris from the annular channel 300. Although the fasteners 250 are shown as screws by way of non-limiting example, according to one or more embodiments, the fasteners may be bolts, rivets, anchors, adhesives, or any other fasteners known in the art. According to one or more embodiments, the upper housing 210 may be integrally formed with the lower housing 220. According to one or more embodiments, the upper housing 210 and the lower housing 220 may be attached by a press fit.

[0045] During use, liquid (such as water) may enter the battery pack housing 120 of the battery pack assembly 100. For example, condensate may drip onto the battery pack housing bottom plate 121 (such as from the cooling system 130). In this case, the liquid can flow slowly and / or intermittently towards the battery pack housing bottom plate 121. Such an event will be referred to as an intermittent liquid event. As another example, a liquid leak may occur in the battery pack assembly 100 or some external system, causing liquid to enter the battery pack housing 120. Such an event will be referred to as a high-flow liquid event. Since the battery pack housing 120 may include battery cells 115 with high voltage, the accumulation of liquid within the battery pack housing 120 is undesirable. Therefore, a drain valve is provided on the battery pack housing bottom plate 121 to drain the liquid. However, although the drain valve can be set to open each time an intermittent liquid event occurs, or to drain the liquid from the battery pack housing 120 if a high-flow liquid event occurs, there is a risk of liquid entering the drain valve from below and into the battery pack housing 120 each time the drain valve opens.

[0046] Accordingly, as described herein, one or more embodiments of the battery pack drain assembly 200 can reduce the opening frequency of the main drain valve 240 while maintaining the ability to drain liquid from the battery pack housing 120 as desired. Additionally, one or more embodiments can prevent any liquid entering from below the main drain valve 240 from reaching the battery pack housing 120 or any of the battery cells 115 or electrical components therein.

[0047] As described above, the upper surface of the second drain valve 230 may be flush with or below the battery pack housing bottom plate 121 around the battery pack drain assembly 200. In this way, the liquid on the battery pack housing bottom plate 121 can open the second drain valve 230 and flow into the annular channel 300 of the lower housing 220. Once most or all of the liquid on the battery pack housing bottom plate 121 has been drained into the battery pack drain assembly 200, the second drain valve 230 can be closed. For intermittent liquid events, the annular channel 300 holds the liquid, and the closed second drain valve 230 prevents the liquid from splashing back into the battery pack housing 120. The main drain valve 240 may not open until the liquid fills the annular channel 300 to the level at or above the shoulder 222 of the valve seat 229. Once the liquid reaches the level at or above the shoulder 222 of the valve seat 229, the liquid will open the main drain valve 240 and drain from the battery pack drain assembly 200. In a high-flow liquid event, the liquid may flow onto the battery pack housing bottom plate 121 at a relatively high flow rate. Due to the relatively high flow rate, the liquid will open the second drain valve 230, fill the annular channel 300 to the shoulder 222, and open the main drain valve 240 to flow out of the battery pack drain assembly 200. In this way, for intermittent liquid events, the opening frequency of the main drain valve 240 can be reduced because the liquid can be stored in the annular channel 300 instead of opening the main drain valve 240. For high-flow liquid events, the annular channel 300 can be filled to the level of the shoulder 222 of the valve seat 229 relatively quickly to open the main drain valve 240, enabling the battery pack drain assembly 200 to effectively drain liquid from the battery pack housing 120 during high-flow liquid events.

[0048] According to one or more embodiments, the battery pack drain assembly 200 can effectively drain the battery pack housing 120 during high-flow liquid events and / or during intermittent liquid events as needed. According to one or more embodiments, by reducing the opening frequency of the main drain valve 240 during intermittent liquid events, the risk of liquid intrusion or foreign contaminants entering the battery pack drain assembly 200 through the open main drain valve 240 can be reduced. According to one or more embodiments, even if there is liquid intrusion into the battery pack drain assembly 200 through the open main drain valve 240, the second drain valve 230, which can be a check valve or a one-way valve, will prevent the liquid from reaching the battery pack housing 120.

[0049] 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, a structure, a step, or a 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 can be combined in any suitable manner in the various aspects.

[0050] When an element such as a layer, a film, a region, or a 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, no intervening elements are present.

[0051] 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.

[0052] 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.

[0053] Although the foregoing disclosure has been described with reference to exemplary embodiments, those of ordinary skill in the art will understand that various changes can be made and equivalents can be substituted for its elements without departing from its scope. Additionally, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from its essential scope. Accordingly, it is intended that the disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery pack discharge assembly, comprising: a discharge housing including an annular outer wall and an annular inner wall; an annular passage defined between the outer wall and the inner wall; as well as a main discharge valve disposed at least partially within the inner wall, Wherein, the main discharge valve is configured to open when the liquid in the discharge housing reaches the upper portion of the inner wall.

2. The battery pack drain assembly according to claim 1, further comprising: A shoulder extends from a top of the inner wall, wherein the shoulder and the inner wall define a valve seat.

3. The battery pack discharge assembly according to claim 2, wherein: An opening is formed in the shoulder, and wherein the main discharge valve passes through the opening. 4 . The battery pack drain assembly according to claim 1 , further comprising a second drain valve disposed on the outer wall.

5. The battery pack discharge assembly according to claim 4, wherein: The second discharge valve is a one-way valve.

6. The battery pack drain assembly according to claim 4, wherein: The second discharge valve is formed by a membrane which allows water vapor to pass through while preventing liquid from passing through when the second discharge valve is closed.

7. The battery pack drain assembly according to claim 1, wherein: The discharge housing includes a lower housing including the inner wall and the outer wall and an upper housing mounted on the lower housing to form a closed space therein.

8. The battery pack drain assembly according to claim 7, further comprising: A second discharge valve is disposed on the outer wall, wherein the upper shell includes a second discharge groove located above the second discharge valve.

9. The battery pack drain assembly according to claim 7, wherein: The upper housing is removably mounted on the lower housing by fasteners.

10. The battery pack drain assembly according to claim 1, wherein: The inner wall is higher than the outer wall.

Images