Release of energy from damaged battery assembly

Abstract

A system for discharging a battery assembly includes a fluid conduit configured to direct liquid to the battery assembly, the fluid conduit including a fluid outlet, and a mixing device configured to be connected in fluid communication with the fluid conduit and the battery assembly. The mixing device is configured to incorporate a substance into the liquid as the liquid flows through the mixing device and before the liquid interacts with the battery assembly. The incorporation of the substance increases the conductivity of the liquid such that when the liquid interacts with the battery assembly, the liquid causes discharge of the battery assembly.

Description

Technical Field

[0001] This disclosure relates to batteries, and more particularly to discharging battery assemblies. Background Art

[0002] Vehicles (including gasoline and diesel-powered vehicles, as well as electric and hybrid vehicles) have battery storage components for purposes such as powering electric motors, electronic devices, and other vehicle subsystems. In some cases, it is desirable to release energy from a vehicle battery system, such as in the case of a damaged battery assembly. For example, if a vehicle is in an accident, it is recommended to fully discharge the battery system to remove stranded energy and reduce the likelihood of overheating. If the charging port or other electrical connections are damaged, the ability to effectively discharge the battery system is impaired. Accordingly, there is a desire to provide a device or system that can provide improved discharging capabilities under conditions where normal discharging is not available. Summary of the Invention

[0003] In one exemplary embodiment, a system for discharging a battery assembly includes a fluid conduit configured to direct a liquid to the battery assembly, the fluid conduit including a fluid outlet, and a mixing device configured to be fluidly connected to the fluid conduit and the battery assembly in fluid communication. The mixing device is configured to incorporate a substance into the liquid as the liquid flows through the mixing device and before the liquid interacts with the battery assembly. The incorporation of the substance increases the electrical conductivity of the liquid such that when the liquid interacts with the battery assembly, the liquid causes the battery assembly to discharge.

[0004] In addition to one or more of the features described herein, the substance is an ionic substance configured to provide a certain concentration of ions to increase the electrical conductivity of the liquid.

[0005] In addition to one or more of the features described herein, the battery assembly is disposed in a vehicle.

[0006] In addition to one or more of the features described herein, the mixing device includes a mixing chamber configured to be connected to the fluid conduit, the mixing chamber housing the substance.

[0007] In addition to one or more of the features described herein, the substance is a solid layer disposed on an inner surface of the mixing chamber and the solid layer is exposed to the liquid as the liquid flows through the mixing chamber.

[0008] In addition to one or more of the features described herein, the substance is particles filling at least a portion of the mixing chamber.

[0009] In addition to one or more of the features described herein, the substance is a concentrated fluid.

[0010] In addition to one or more features described herein, the mixing device is configured as an attachment for a fluid conduit.

[0011] In addition to one or more features described herein, the mixing device is configured to be connected to a fluid port that is in fluid communication with a fluid channel extending from the fluid port to the battery assembly.

[0012] In another exemplary embodiment, a method for discharging a battery assembly includes obtaining a fluid conduit that is connected to a liquid source, the fluid conduit including a fluid outlet, and flowing the liquid through the fluid conduit to a mixing device that is fluidly connected to the fluid conduit and the battery assembly. The method further includes binding a substance to the liquid through the mixing device as the liquid flows through the mixing device, wherein binding the substance increases the conductivity of the liquid, and directing the liquid to interact with the battery assembly and cause discharge of the battery assembly.

[0013] In addition to one or more features described herein, the substance is an ionic substance that is configured to provide a certain concentration of ions to increase the conductivity of the liquid.

[0014] In addition to one or more features described herein, the mixing device includes a mixing chamber connected to the fluid conduit, and the mixing chamber houses the substance.

[0015] In addition to one or more features described herein, the substance is configured as a solid layer disposed on an inner surface of the mixing chamber, and when the liquid flows through the mixing chamber, the solid layer is exposed to the liquid.

[0016] In addition to one or more features described herein, the substance is particles that fill at least a portion of the mixing chamber.

[0017] In addition to one or more features described herein, the substance is a concentrated fluid.

[0018] In addition to one or more features described herein, the mixing device is configured as an attachment for a fluid conduit.

[0019] In addition to one or more features described herein, the mixing device is connected to a fluid port, and the liquid is directed from the fluid port to the battery assembly through a fluid channel extending from the fluid port to the battery assembly.

[0020] In yet another exemplary embodiment, a vehicle system includes a battery assembly that includes one or more battery cells disposed in a housing, a fluid passage extending from the housing and configured to convey a liquid into the housing, and a fluid port in fluid communication with the fluid passage. The fluid port includes a mixing chamber that houses a substance configured to increase the conductivity of the liquid, the mixing chamber being configured to incorporate the substance into the liquid as the liquid flows through the mixing chamber into the fluid passage and before the liquid interacts with the battery assembly, wherein incorporation of the substance increases the conductivity of the liquid such that the liquid causes discharge of the battery assembly. The substance is configured as a solid layer of the substance disposed at an inner surface of the housing, a solid substance, and / or a liquid mixture.

[0021] In addition to one or more of the features described herein, the fluid port is configured to connect to a fluid conduit that is configured to connect to a liquid source.

[0022] In addition to one or more of the features described herein, the substance is configured as one of: the solid layer, particles filling at least a portion of the liquid chamber, and a concentrated fluid.

[0023] The above features and advantages of the present disclosure, as well as other features and advantages, are apparent from the following detailed description when taken 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, in which:

[0025] Figure 1 is a top view of a motor vehicle according to an exemplary embodiment;

[0026] Figure 2 depicts a system for discharging a battery assembly according to an exemplary embodiment;

[0027] Figure 3 depicts components of a system that is part of or attached to a flood port of a vehicle according to an exemplary embodiment;

[0028] Figure 4 depicts a system for discharging a battery assembly according to an exemplary embodiment; and

[0029] Figure 5 is a flow chart depicting aspects of a method for thermal management of a battery assembly according to an exemplary embodiment. DETAILED DESCRIPTION

[0030] 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 represent the same or corresponding components and features.

[0031] According to an exemplary embodiment, a method, apparatus, and system for discharging a battery assembly or system (such as a battery pack in an electric vehicle or a hybrid vehicle) are provided. The methods, apparatuses, and systems described herein can be applicable to situations or conditions where existing electrical connections are damaged or unavailable. For example, some embodiments are applicable to situations where an electric or hybrid vehicle is damaged and the normal electrical connections of the vehicle (such as a charging port) are also damaged or inaccessible.

[0032] Embodiments of the discharge system include a fluid conduit or other mechanism for delivering a liquid, such as water, to the battery assembly. The system also includes means for increasing the conductivity of the liquid before the liquid is introduced into the battery cells. In one embodiment, the means is configured to introduce an ionic compound (such as a salt) or other substance providing an ionic concentration into the water, or otherwise increase the conductivity. For example, the salt or other substance can be included in an attachment of a fluid port, hose, or other conduit of the vehicle such that at least some of the substance dissolves in the liquid and increases the liquid conductivity.

[0033] The embodiments described herein present numerous advantages and technical effects. The embodiments provide an effective method for releasing energy from a battery assembly, particularly in situations where other discharge options are unavailable.

[0034] The embodiments are not limited to use with any particular vehicle and can be applicable to various contexts. For example, the embodiments can be used with automobiles, trucks, airplanes, construction equipment, farm equipment, automated factory equipment, medical devices, power systems, and / or any other device or system including a battery assembly.

[0035] Figure 1 An embodiment of a motor vehicle 10 is shown, the motor vehicle 10 including a body 12 that at least partially defines an occupant compartment 14. The body 12 also supports various vehicle subsystems, including a propulsion system 16, and other subsystems for supporting the functions of the propulsion system 16 and other vehicle components, such as a braking subsystem, a suspension system, a steering subsystem, a fuel injection subsystem, an exhaust subsystem, and the like.

[0036] The vehicle 10 can be an internal combustion engine vehicle, an electric vehicle (EV), or a hybrid vehicle. In one embodiment, the vehicle 10 is a hybrid vehicle including an internal combustion engine system 18 and at least one electric motor assembly. In one embodiment, the propulsion system 16 includes an electric motor 20 and can include one or more additional electric motors positioned at various locations. The vehicle 10 can be an all-electric vehicle having one or more electric motors.

[0037] Vehicle 10 includes a battery system 22 that may be electrically connected to a motor 20 and / or other components, such as vehicle electronics. The battery system 22 may be configured as a rechargeable energy storage system (RESS). In one embodiment, the battery system 22 includes a battery assembly, such as a high-voltage battery pack 24 having a plurality of battery modules 26. The battery pack 24 may be disposed in a housing 28. The battery system 22 may also include a monitoring unit 29 that includes components such as a processor, memory, interface, bus, and / or other suitable components.

[0038] It should be noted that a "battery assembly" may be a single battery cell or a group of cells. For example, the battery assembly may be the battery pack 24, a battery module 26, or a single cell or group of cells within the module 26.

[0039] The battery system 22 is electrically connected to components of the propulsion system 16. The propulsion system 16 includes an inverter module 30 and may also include a direct current (DC)-to-DC converter module 32. The inverter module 30 (e.g., a traction power inverter unit or TPIM) converts direct current (DC) power from the battery system 22 into polyphase alternating current (AC) power (e.g., three-phase, six-phase, etc.) to drive the motor 20.

[0040] Various control modules (electronic control modules or ECUs) may be included in the vehicle 10. For example, an on-board charging module (OBCM) 34 may be included that electrically connects the battery system 22 to a charging port 36 and controls aspects of charging the battery system 22 (e.g., from a charging station or other vehicle) and / or providing charge to an external system (e.g., vehicle-to-vehicle charging).

[0041] Vehicle 10 also includes a computer system 40 that includes one or more processing devices 42 and a user interface 44. Various processing devices and units may communicate with each other via a communication device or system, such as a controller area network (CAN) or Transmission Control Protocol (TCP) bus.

[0042] Vehicle 10 may include components or systems that facilitate exposing the battery pack 24 to a fluid. The fluid may be water, a water-based solution, foam, and / or any other desired fluid or combination of fluids. These components may be used for various purposes, such as discharging the battery pack 24 or extinguishing a fire as described herein.

[0043] For example, vehicle 10 includes a fluid injection system 50 having an internal fluid conduit that is referred to herein as a fluid passage 52. The fluid passage 52 is connected at one end to an inlet 54 at the housing 28, which allows water or other fluid to flood the battery pack 24. The fluid passage 52 may take various forms, such as a tube (e.g., plastic or rubber) or a duct.

[0044] The other end of the fluid passage 52 terminates at a flood port 56. The flood port 56 is arranged to be close to the exterior of the vehicle (e.g., at or near the rear bumper or the trunk), and provides a connection to an external fluid source. The flood port 56 can be arranged at any suitable location and is thus not limited to Figure 1 the location shown in

[0045] Embodiments include means or mechanisms for applying a liquid to a battery assembly to facilitate discharging of the battery assembly. The means or mechanisms are provided to combine a substance with a liquid (e.g., water) to increase the electrical conductivity of the liquid, thereby providing an electrically conductive path for releasing any energy held in the battery assembly.

[0046] The substance dissolves, mixes, or otherwise combines with the fluid such that the fluid provides an electrically conductive path for the battery assembly to release energy. For example, the electrically conductive path allows current to flow from the positive electrode to the negative electrode of the cells and / or modules 26 in the battery pack. The electrically conductive path can be grounded or electrically insulated.

[0047] The substance can be an ionic substance that provides an ionic concentration that provides electrical conductivity and provides an electrical path having a resistance that is selected to allow discharging at a desired rate. The substance can be any suitable substance that provides an electrically conductive path, such as salts, acids, conductive nanoparticles, etc.

[0048] Figure 1 and Figure 2 Aspects of an embodiment of a discharging system 60 are depicted, the discharging system 60 being configured to provide a fluid such as water or other suitable liquid to facilitate discharging of a battery assembly such as the battery pack 24. In one embodiment, as Figure 1 and Figure 2 shown, the discharging system includes a mixing chamber 70 for combining a substance with the liquid to increase the electrical conductivity of the liquid and to facilitate discharging.

[0049] Referring Figure 2 , in one embodiment, the discharging system 60 includes or is connectable to a fluid conduit 62, such as a hose. The fluid conduit 62 is connected to a fluid source 64, which in one embodiment is water, a water-based liquid, or other suitable liquid. The fluid source 64 can be a tank, a fire hydrant, an emergency response vehicle, a water truck, or other source.

[0050] The discharging system 60 can include components of the fluid injection system 50. For example, the flood port 56 includes a conduit fitting 66 that is configured to engage an outlet 68 of the fluid conduit 62.

[0051] The discharge system 60 includes a mixing device having a mixing chamber 70. The mixing chamber 70 encloses or contains a substance that increases the conductivity of a liquid when mixed or combined with the liquid. For example, the mixing chamber contains salts (e.g., sodium chloride), acids, or other substances configured to dissolve in the liquid or otherwise combine with the liquid to provide a certain concentration of ions. The concentration can be selected to provide a desired resistivity to the liquid.

[0052] In one embodiment, the mixing chamber 70 is included in or fluidly connected to the perfusion port 56. For example, the mixing chamber 70 can be included in the perfusion port or disposed between the perfusion port 56 and the fluid channel 52. In another example, the mixing chamber 70 can be formed in a separate component (e.g., similar to an adapter) that can be attached to the perfusion port 56.

[0053] In one embodiment, aspects of the discharge battery pack 24 can be performed exclusively by a human operator, by a processing device or system, or both. For example, a controller 65 can be provided to control some aspects of connecting the fluid conduit 62 (e.g., by controlling an actuator to engage the perfusion port 56) and / or controlling the fluid flow (e.g., controlling a pump).

[0054] Figure 3 An example where the mixing chamber 70 is part of the perfusion port 56 is shown, and an example of the configuration of the substance for increasing the conductivity of the liquid is also shown.

[0055] In this example, the mixing chamber 70 is formed within a fitting 72. The fitting 72 is coupled to the fluid channel 52 and is configured to engage the outlet 68 of the fluid conduit 62. The perfusion port 60 can include various components, such as sealing features, and a locking mechanism, such as a sliding sleeve 74.

[0056] The mixing chamber houses or contains a substance 76 that is configured to increase the conductivity of water (or other desired liquid) when water flows through the mixing chamber 70 and into the fluid channel 52. For example, as Figure 3 shown, the substance 76 is formed as a solid layer or membrane. When water flows through the mixing chamber 70, some of the substance dissolves or otherwise combines with the water to increase the conductivity. The thickness of the layer can be selected based on various criteria, such as the desired concentration of ions (or conductive particles), the flow rate of the water, various intended uses, etc.

[0057] In one embodiment, the mixing chamber 70 is incorporated into the outlet 68 of the fluid conduit or is configured as an attachment to the outlet 68 of the fluid conduit. Figure 4 An example of the system 60 including a mixing assembly 80 attached to the outlet 68 is depicted. The mixing assembly 80 can be a removable attachment or can be fixed to the outlet 68.

[0058] Mixing chamber 70 is formed in a flow member 82 that is in fluid communication with an outlet 68 and a nozzle 84. In this example, a substance is dissolved in a concentrated fluid mixture or ionic solution 86 in a container 88 attached to the flow member 82.

[0059] Whether incorporated as part of the perfusion port 56, as part of the outlet 68, or as an attachment, the mixing chamber 70 can include a substance in any of a variety of forms. Such forms can include a layer or solution as described above, or other forms such as powders or granules, dissolvable solid structures (e.g., beads, meshes, sieves, etc.), or any other suitable form.

[0060] Figure 5 An embodiment of a method 100 for discharging a battery assembly is shown. Method 100 (or portions thereof) can be performed manually by a human operator (e.g., an owner, an emergency responder, a technician, etc.) and / or by any suitable one or more processing devices.

[0061] Method 100 includes a plurality of steps or stages represented by blocks 101 - 104. Method 100 is not limited to the number or order of the steps therein, as some of the steps represented by blocks 101 - 104 can be performed in an order different from the order described below, or fewer than all of the steps can be performed.

[0062] For illustrative purposes, method 100 is discussed in connection with Figure 3 or Figure 4 vehicle 10 and discharge system 60. Method 100 is not limited thereto, as method 100 can be applied to any device or system that utilizes battery storage (e.g., electrical equipment, various vehicles, manufacturing equipment, etc.). Additionally, method 100 can be performed using any suitable mechanism that allows a liquid to be combined with a substance for enhancing conductivity and the resulting liquid mixture or solution to be applied to the battery assembly. Additionally, although method 100 is discussed in connection with water as the liquid to be applied to the battery assembly, any suitable liquid can be used.

[0063] Method 100 can be performed by various persons or systems. For example, method 100 can be performed by a first responder or a second responder to remove trapped energy from a battery damaged due to an accident or vehicle failure. Other applications of method 100 can include unloading prior to the rescue of a vehicle or other device.

[0064] At block 101, a supply of water is obtained. For example, a conduit such as a fluid conduit 62 (e.g., a hose) is connected to a water source. The water source can be any suitable source, such as a water tank, a municipal fire hydrant, an emergency response vehicle (e.g., a water truck), etc.

[0065] At block 102, the operating fluid conduit 62 is operated to direct water flow to a battery assembly, such as a battery pack in an electric vehicle, an electrical device, or other electrical apparatus or system. For example, water flows to the battery pack 24 (e.g., via the filling port 56, if available, or by spraying with the nozzle 84).

[0066] At block 103, when water flows through the attachment, nozzle, or filling port, the ionic compound combines with the water. As a result, the water forms an ionic solution with increased conductivity.

[0067] For example, if the vehicle includes a filling port 56, the water combines with a substance contained within the filling port 56 (or in an attachment or component attached to the filling port). If the vehicle 10 does not include a filling port, a hose with an attachment including the ionic compound (or other suitable substance) or a nozzle including the substance is used to fill the battery pack 24.

[0068] At block 104, the trapped energy in the battery pack 24 discharges. The discharge is facilitated by a conductive path provided by the combined liquid with increased conductivity. For example, the ionic solution enables current to flow from the positive electrode to the negative electrode of the cells and / or modules within the battery pack 24. Energy in the form of heat (and potentially gas or vapor) is generated and exits the battery pack 24.

[0069] The term "a" does not denote a limitation of quantity, but rather denotes the presence of at least one of the referenced items. Unless the context clearly dictates otherwise, the term "or" means "and / or". References to "aspect" throughout the specification mean that the particular elements described in connection with that aspect (e.g., features, structures, steps, or characteristics) 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 may be combined in any suitable manner in the various aspects.

[0070] 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, no intervening elements are present.

[0071] Unless otherwise stated herein, all test standards are the latest standards in effect 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 standards appear.

[0072] 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. Although 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 elements may be substituted with equivalents 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 its basic scope. Therefore, it is intended that this disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A system for discharging a battery assembly, the system comprising: a fluid conduit configured to direct a liquid to the battery assembly, the fluid conduit comprising a fluid outlet; a mixing device configured to be connected in fluid communication with the fluid conduit and the battery assembly, the mixing device configured to incorporate a substance into the liquid as the liquid flows through the mixing device and before the liquid interacts with the battery assembly, wherein the incorporation of the substance increases the conductivity of the liquid such that when the liquid interacts with the battery assembly, the liquid causes discharge of the battery assembly.

2. The system according to claim 1, wherein: The substance is an ionic substance configured to provide a concentration of ions to increase the conductivity of the liquid.

3. The system according to claim 1, wherein: The battery assembly is disposed in a vehicle.

4. The system of claim 1, wherein the mixing device comprises a mixing chamber configured to be connected to the fluid conduit, the mixing chamber containing the substance.

5. The system of claim 4, wherein the substance is configured as a solid layer disposed on an inner surface of the mixing chamber, and the solid layer is exposed to the liquid as the liquid flows through the mixing chamber.

6. The system of claim 4, wherein the substance is a concentrated fluid or particles that fill at least a portion of the mixing chamber.

7. The system of claim 1, wherein the mixing device is configured as an attachment to the fluid conduit.

8. The system of claim 1, wherein the mixing device is configured to be connected to a fluid port that is in fluid communication with a fluid passage extending from the fluid port to the battery assembly.

9. A method for discharging a battery assembly, the method comprising: obtaining a fluid conduit connected to a liquid source, the fluid conduit comprising a fluid outlet; flowing the liquid through the fluid conduit to a mixing device connected in fluid communication with the fluid conduit and the battery assembly; incorporating a substance into the liquid through the mixing device as the liquid flows through the mixing device, wherein incorporating the substance increases the conductivity of the liquid; and The liquid is directed to interact with the battery component and cause discharge of the battery component.

10. The method according to claim 9, wherein: The substance is an ionic substance configured to provide a concentration of ions to increase the conductivity of the liquid.

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