Substrate for battery system

Abstract

A substrate for a battery system is described. The substrate includes a base body and at least two channels extending in a first direction and offset from each other in a second direction. The second direction is preferably perpendicular to the first direction. The channel is configured for directing a gas, such as an exhaust gas, away from at least one energy storage unit of the battery system. The at least two channels include a main volume and a support structure. The support structure is arranged at a first side of the main volume and includes at least one first contact surface and at least one main surface. The at least one first contact surface is contactable with the energy storage unit. The at least one first contact surface is offset relative to the at least one major surface in a third direction. The third direction is perpendicular to the first direction and the second direction.

Description

Technical Field

[0001] The field of the present invention relates to a substrate for a battery system, a battery system for a vehicle, and a vehicle including the battery system. Background Art

[0002] In recent years, there has been an increasing awareness of the need to transition to sustainable and environmentally friendly practices. A key aspect of this transition is the adoption of electric vehicles as an alternative to traditional internal combustion engine vehicles. Electric vehicles offer significant benefits such as reduced greenhouse gas emissions and lower operating costs. The core of these electric vehicles lies in their energy storage system - the battery, which is also the main cost factor. The batteries for future electric vehicles need to meet increasingly high mechanical and cost-related requirements.

[0003] The mechanical stability and stiffness of an electric vehicle battery, as well as a robust design, contribute to ensuring overall vehicle safety and ensuring optimal performance, while minimizing the risk of damage or failure during mechanical stresses such as sudden impacts or road irregularities. The battery must withstand various mechanical stresses, including vibrations, impacts, and extreme temperature variations, to ensure safe and long-term functionality. A robust housing material and design contribute to protecting the delicate and expensive internal components and preventing dangerous situations such as short circuits or thermal runaway. An adequate cooling and thermal management system is essential for maintaining optimal operating conditions.

[0004] The mechanical stability and rigidity of the battery ensure that the battery can withstand the demands of daily driving, maintain its efficiency and safety, while also contributing to the overall stability and crashworthiness of the vehicle. Additionally, a rigid battery structure helps prevent excessive chassis flexure, resulting in more predictable and responsive handling, and ultimately enhancing the overall driving experience and safety of the vehicle.

[0005] The internal design of a battery pack affects the overall mechanical stability and rigidity of the battery. The arrangement of battery modules and individual battery cells within the battery pack is crucial. A well-organized layout of battery modules and cells helps to evenly distribute mechanical loads, thereby reducing stress concentrations. The battery pack can further include internal structural reinforcements such as metal or composite frames to provide additional support and rigidity. These reinforcements help prevent deformation or distortion during the dynamic movement of the vehicle, thereby improving the mechanical stability of the battery.

[0006] The connection and fastening methods of battery cells and battery modules inside the battery pack further affect the mechanical stability and rigidity of the battery. The interconnection and fastening mechanisms ensure that the battery components are firmly held in place and enable the load to be distributed throughout the battery. The precision and quality of the battery manufacturing process are also essential. Precise assembly and tight tolerances reduce the risk of structural defects and ensure consistent performance regarding mechanical stability and rigidity.

[0007] The battery cells of an electric vehicle battery can be joined to each other and to the housing using foam overmolding. During battery assembly, a polymeric foam material can be applied around each battery cell to enhance the protection of the battery cells and improve the mechanical stability and rigidity of the overall battery. The battery cells are placed and positioned within a mold such as the housing, and then a liquid foam material is injected into the mold to encapsulate the battery cells. When the foam cures, it adheres to the battery cells, creating a protective cushioning layer and connecting the battery cells to each other and to the housing. Foam overmolding further provides impact resistance, thermal insulation, and vibration damping, protecting the battery cells from mechanical stress while maintaining an effective operating temperature.

[0008] The positioning of the battery cells before and during foam overmolding is an important step in the manufacturing process to ensure the mechanical stability and stiffness of the battery. According to the design requirements of the battery, the individual battery cells are arranged in a specific configuration into the mold. This arrangement typically includes the orientation and physical placement of the battery cells within the mold. Structural elements can be used to maintain the precise spacing, positioning, and alignment of the battery cells. These structural elements help ensure that the battery cells remain properly positioned and maintain consistent spacing during the foam overmolding process. Controlled battery cell positioning further ensures that the foam encapsulation effectively provides protection, insulation, and vibration damping for the battery cells.

[0009] The amount of surface area of the battery cell encapsulated with foam further contributes to the overall performance and safety of the battery. The foam provides a protective barrier around the battery cell. The larger the surface area of the individual battery cell covered by the foam, the better the mechanical connection between the battery cells and between the battery and the housing, and the stronger the mechanical protection against shock, vibration, and external forces. This helps prevent physical damage to the battery cell, thus maintaining its structural integrity and functionality. The foam further serves as an insulator, and the coverage of the battery cell surface with foam helps maintain a more uniform internal temperature within the battery. This insulation minimizes heat transfer between the battery cells, thereby reducing the risk of thermal runaway and ensuring more stable operating conditions. Therefore, the amount of surface area of the battery cell encapsulated with foam and the volume available for foaming around the battery cell are important design parameters of the battery that affect the protection, thermal management, safety, and mechanical stability of the battery, all of which are important for the performance and long-term reliability of an electric vehicle battery.

[0010] An electric vehicle battery also needs to prevent dangerous thermal conditions such as thermal runaway. Thermal runaway in a battery is an uncontrolled self-accelerating process characterized by a rapid increase in temperature due to internal chemical reactions. Thermal runaway can lead to overheating, gas generation, and potential catastrophic failure, posing serious safety risks. When a battery cell experiences thermal runaway, the exhaust gas from that battery cell needs to be discharged from the battery pack through a designated emergency exhaust port or outlet to prevent these gases from causing a thermal event in additional battery cells. The exhaust gas can be directed through an exhaust passage, which allows the exhaust gas to expand and directs the exhaust gas towards the designated emergency exhaust port or the outlet of the housing. Additional components need to be provided in the battery pack to provide these exhaust passages and ensure that these exhaust passages are not blocked by the foam entering the passages during the foam overmolding process.

[0011] It is beneficial to provide components in battery design that serve multiple functions to reduce the cost and complexity of the battery. However, known electric vehicle batteries use separate components to provide the exhaust passages and to position the battery cells before and during the foam molding process. Known electric vehicle batteries do not provide sufficient free volume around the battery cells for foam overmolding. Summary of the Invention

[0012] In view of this background art, an object of the present invention is to provide an improved substrate for a battery system, an improved battery system for a vehicle, and a vehicle including the improved battery system.

[0013] This object is achieved by a substrate for a battery system having the features as claimed in claim 1. This object is further achieved by a battery system having the features as claimed in claim 13 and a vehicle having the features as claimed in claim 19.

[0014] A substrate for a battery system is disclosed herein. The substrate includes a base body and at least two channels that extend in a first direction and are offset from each other in a second direction. The second direction is preferably perpendicular to the first direction. The channels are configured to direct a gas such as exhaust away from at least one energy storage unit of the battery system. The at least two channels include a main volume and a support structure. The support structure is disposed at a first side of the main volume and includes at least one first contact surface and at least one main surface. The at least one first contact surface is capable of contacting the energy storage unit. The at least one first contact surface is offset in a third direction relative to the at least one main surface. The third direction is perpendicular to the first direction and the second direction.

[0015] Accordingly, the present invention relates to a component for a battery system, wherein the component provides multiple functions. The support structure of the substrate supports the energy storage unit in the third direction and enables a defined positioning of the energy storage unit relative to the third direction (also referred to as datuming of the energy storage unit). The support structure also allows for providing and increasing the free volume below the energy storage unit available for structural foam overmolding. Accordingly, the adhesive surface area in contact with the foam around the bottom of the energy storage unit can be increased. Thus, the substrate addresses the challenge in the manufacture of battery systems, namely the compromise between the positioning of the energy storage unit and the overmolding of the energy storage unit. The benefit of maximizing the volume of the structural foam results in improved mechanical stability of the energy storage unit and the structural performance of the battery system.

[0016] The substrate also provides channels configured as exhaust channels to allow exhaust gases to be directed away towards a designated emergency exhaust port or outlet of the housing of the battery. Thus, the substrate allows for providing the function of positioning the energy storage unit in the third direction, providing an exhaust channel for the energy storage unit, and allowing enhanced foam overmolding around the bottom of the energy storage unit with only one integral component.

[0017] The substrate is also designed to be manufactured using well - established plastic blow - molding techniques and / or thermo - forming techniques and / or vacuum - forming techniques, thus providing cost - effectiveness and scalability for a wide range of different battery system sizes.

[0018] The term "substrate" refers to a component of a battery system such as a vent plate. The substrate is configured to support a plurality of energy storage cells and also provide a channel for directing exhaust gas to exit. The substrate preferably has a plate-like shape having a larger dimension in a plane defined by a first direction and a second direction, and having a smaller dimension in a third direction than the dimensions in the first direction and the second direction.

[0019] The substrate can be made of a plastic material suitable for plastic blow molding, such as acrylic (PMMA), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate glycol (PETG), polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC). The substrate can alternatively or additionally be made of different materials and / or using different manufacturing techniques.

[0020] The term "battery system" refers to a device designed to store electrical energy and supply electrical energy to a load connected to the battery system. The battery system is preferably further designed to receive electrical energy, which is then stored. The battery system can be an electrochemical device, such as a battery or a rechargeable battery. When connected to a circuit, the battery system transmits electrons, generating current. The battery system can be an AC battery that supplies alternating current, or it can be a DC battery that supplies direct current. The battery system can alternatively be or include a battery that can supply both alternating current and direct current. The battery system according to the present invention can be flexibly used in different application scenarios. The battery system can be a battery pack including a plurality of battery modules, or it can alternatively be a battery module including a plurality of energy storage units. The battery system can be particularly not limited to (not exclusively) being used as and / or suitable as a traction battery (traction battery, power battery) for a battery electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV), a hybrid electric vehicle (HEV) or a fuel cell unit electric vehicle (FCEV).

[0021] The term "substrate" refers to a plate-like structure that houses or includes at least two channels and a supporting structure.

[0022] The term "channel" refers to a longitudinal structure extending substantially in a first direction. The channel has a wall having a hollow cross-section in a plane perpendicular to the first direction. The hollow cross-section has a generally trapezoidal shape to enhance vacuum forming during manufacture of the substrate. Alternatively or additionally, the hollow cross-section can have a substantially rectangular shape or any other suitable shape. The channel is configured to guide a fluid such as a gas along the first direction. The substrate can be partly a wall of the channel.

[0023] The term "main volume" refers to the free volume or empty volume that is enclosed within the channel and provided for receiving and guiding fluid along the first direction. The main volume is not filled with any solid material and can be filled with air.

[0024] The term "support structure" refers to a structure that is integrally provided as part of the wall of the channel at the first side of the channel. The support structure allows an energy storage unit to be placed on the support structure to support and position the energy storage unit in the third direction, while ensuring sufficient free volume for foam overmolding below the energy storage unit (i.e., between the channel and the energy storage unit and / or between the substrate and the energy storage unit).

[0025] The term "first side" refers to the side of the channel that is substantially facing the third direction and facing away from the substrate. The energy storage unit to be placed on the substrate will be arranged at the first side.

[0026] The term "contact surface" refers to such a surface of the support structure: a surface that is substantially facing the third direction and is configured to contact at least one energy storage unit in a state where at least one energy storage unit is arranged on the substrate, supported by the substrate, and positioned by the substrate in the third direction. At least one first contact surface can be a flat surface or can have a curvature. The at least one first contact surface is a specifically formed part of the wall of the channel.

[0027] The term "energy storage unit" refers to each component and / or unit that stores and / or delivers electrical energy within a battery system. These energy storage units can include single battery cells, battery modules having multiple battery cells, supercapacitors, photovoltaic battery cells, fuel cell units, electromechanical power converters, and / or capacitive energy sources or any other energy storage device capable of storing and delivering electrical energy. The battery cell can be a cylindrical battery cell.

[0028] The term "capable of contacting an energy storage device" refers to the ability of the support structure to contact at least one of the energy storage devices of the battery system to be arranged on the substrate. This contact preferably enables the substrate to support at least one energy storage device and define the position of at least one storage device within the battery system in the third direction. The support structure can be in direct contact with the energy storage unit. However, in the case of the state where the energy storage unit is arranged on the substrate, supported by the substrate, and positioned by the substrate in the third direction, if other components are also arranged between the support structure and the energy storage unit, then the support structure can also alternatively or additionally be in indirect contact with the energy storage unit.

[0029] The term "main surface" refers to another surface of the support structure that is substantially oriented in a third direction and is configured not to contact at least one energy storage unit in a state where at least one energy storage unit is disposed on the substrate, supported by the substrate, and positioned by the substrate in the third direction. The main surface can be a flat surface or can have a curvature. At least one main surface is a specifically formed part of the wall of the channel. At least one main surface is offset in a first direction, in a second direction, and in a third direction with respect to at least one first contact surface to ensure that in a state where at least one energy storage unit is disposed on the substrate, supported by the substrate, and positioned by the substrate in the third direction, the main surface does not contact at least one energy storage unit. Thus, a free volume is reserved between the main surface of at least one energy storage unit and the bottom surface for foam overmolding to increase the amount of foam below at least one energy storage unit.

[0030] According to a first aspect, at least two channels can be spaced apart in a second direction to form at least one open volume. At least one open volume extends in a first direction.

[0031] The term "open volume" refers to a volume that extends substantially in a first direction and is bounded or surrounded by the substrate on three sides (specifically, bounded or surrounded by two of at least two channels and by the substrate body). The open volume is not bounded or closed on the side facing the third direction.

[0032] The open volume allows the foam injected into the battery system during foam overmolding to flow or expand substantially along the first direction through the open volume. Thus, the distribution of the foam within the battery system can be promoted.

[0033] According to a second aspect, the substrate can have a first end and a second end. The first end and the second end are offset from each other in a first direction, and at least two channels have openings only at the first end and / or the second end. In other words, at least two channels do not include any openings in at least two channel walls along the extension of at least two channels in the first direction.

[0034] Thus, during the injection, expansion, and curing of the foam during the foam overmolding process, the foam cannot enter the main volume of at least two channels. This prevents at least two channels from being blocked by the foam within at least two channels. Thus, the ability of at least two channels to guide exhaust can be reliably maintained.

[0035] According to a third aspect, at least one first contact surface and at least one main surface can be arranged in a repeating pattern. This enables sufficient support to be provided for at least one energy storage unit while ensuring sufficient free volume below at least one energy storage unit for the foam to enter. By using a repeating pattern, the manufacturing cost can be further reduced.

[0036] For two adjacent channels among at least two channels, the repeating pattern can be different or offset. Optionally or additionally, for two adjacent channels among at least two channels, the repeating pattern can be the same. The pattern for two adjacent channels among at least two channels can be offset by at least half of the diameter of at least one energy storage unit. This enables a space-saving packaging of at least one energy storage unit in the battery system.

[0037] According to a fourth aspect, the support structure can further include at least one second contact surface. At least one second contact surface can be in contact with the energy storage unit.

[0038] According to a fifth aspect, at least one first contact surface and at least one second contact surface can be offset from each other in a first direction and / or a second direction.

[0039] In addition to at least one first contact surface, at least one second contact surface is provided to enhance the support and stability of at least one energy storage unit, and the at least one second contact surface supports at least one energy storage unit at a second position. By arranging at least one first contact surface and at least one second contact surface to be offset from each other in a second direction and separated from each other by at least one main surface, sufficient free volume below at least one energy storage unit is further provided.

[0040] According to a sixth aspect, at least one second contact surface and at least one main surface can be arranged in a repeating pattern that is offset in a first direction relative to the repeating pattern of at least one first contact surface and at least one main surface.

[0041] According to a seventh aspect, the substrate can further include a plurality of first contact surfaces. The plurality of first contact surfaces can have a rectangular shape that extends substantially in a first direction.

[0042] Multiple first contact surfaces allow for firmly supporting multiple energy storage units on a substrate. The rectangular shape and in particular the basic extension in a first direction of the rectangular shape of the multiple first contact surfaces allow the multiple energy storage units to be placed on the substrate and to be moved to their desired positions during the assembly of the battery system by sliding or shifting in the first direction over the multiple first contact surfaces. The multiple first contact surfaces may alternatively or additionally have rounded edges and / or different shapes, such as oval or any other suitable shape.

[0043] According to an eighth aspect, adjacent first contact surfaces among the multiple first contact surfaces in the first direction can be spaced apart by a void.

[0044] The term "void" refers to the empty space between adjacent first contact surfaces among the multiple first contact surfaces, thereby allowing the foam inserted or injected into the battery system during overmolding to flow or expand substantially along a second direction through the void. Thus, the foam can reach the free volume between at least one main surface and at least one energy storage unit through the void. The foam can further flow or expand from one of at least one open volume through the void to another of at least one open volume. Thus, the distribution of the foam within the battery system can be further facilitated.

[0045] According to a ninth aspect, the support structure can further include multiple third contact surfaces capable of contacting the energy storage units and multiple second contact surfaces capable of contacting the energy storage units. The multiple second contact surfaces and the multiple third contact surfaces can have a rectangular shape extending substantially in the first direction. The multiple first contact surfaces can be arranged in rows extending in the first direction, the multiple second contact surfaces can be arranged in rows extending in the first direction, and the multiple third contact surfaces can be arranged in rows extending in the first direction. The rows of the multiple first contact surfaces, the rows of the multiple second contact surfaces, and the rows of the multiple third contact surfaces can be offset from each other in the second direction. Adjacent second contact surfaces among the multiple second contact surfaces in the first direction can be spaced apart by a void, and adjacent third contact surfaces among the multiple third contact surfaces in the first direction can be spaced apart by a void. The multiple third contact surfaces and at least one main surface can be arranged in a repeating pattern that is offset in the first direction with respect to the repeating pattern of the multiple first contact surfaces and at least one main surface and with respect to the repeating pattern of the multiple second contact surfaces and at least one main surface.

[0046] In addition to the plurality of first contact surfaces and the plurality of second contact surfaces, a plurality of third contact surfaces for supporting at least one energy storage unit are provided at a third position, which can further enhance the support and stability of at least one energy storage unit. By arranging the rows of the plurality of first contact surfaces, the plurality of second contact surfaces, and the plurality of third contact surfaces to be offset from each other in a second direction and separated from each other by at least one main surface, sufficient free volume is further provided below at least one energy storage unit.

[0047] The foam injected into the battery system during foam overmolding is also allowed to flow or expand substantially along the second direction through the gaps between adjacent contact surfaces among the plurality of first contact surfaces, the plurality of second contact surfaces, and the plurality of third contact surfaces. Therefore, the foam can reach the free volume between at least one main surface and at least one energy storage unit through the gaps. The foam can further pass through the gaps to flow or expand from one of at least one open volume to another of at least one open volume. Thus, the distribution of the foam within the battery system can be further promoted.

[0048] Arranging the corresponding repeating patterns of the plurality of first contact surfaces, the plurality of second contact surfaces, and the plurality of third contact surfaces to be offset from each other in a first direction reduces the risk that at least one energy storage unit gets stuck on one of the plurality of first contact surfaces, the plurality of second contact surfaces, and the plurality of third contact surfaces when sliding or displacing at least one energy storage unit during the assembly of the battery system. This further facilitates the easier sliding or displacement of at least one energy storage unit on the plurality of first contact surfaces, the plurality of second contact surfaces, and the plurality of third contact surfaces during the assembly of the battery system, and thus promotes an easier and less time-consuming assembly process.

[0049] According to a tenth aspect, at least one open volume can extend below the bottom surface of the substrate in a third direction such that at least one open volume extends further in the third direction than at least two channels.

[0050] The term "bottom surface" refers to the surfaces of the base body and the substrate that face away from at least one energy storage unit and face a part of the housing of the battery system. At least one open volume extending in a third direction below the bottom surface of the base body allows foam to enter the space below the base body. The cured foam can be used as a contact portion to contact the housing of the battery system, such that the base body does not contact the housing in the assembled state of the battery system. The cured foam between the housing and the substrate can thus be used as a vibration absorbing spacer between the substrate and the housing. By reducing the vibrations transmitted from the housing to the substrate and the energy storage unit to enhance the durability of the battery system, during the life of the battery system, the energy storage unit may be damaged by those vibrations. The cured foam between the housing and the substrate also provides structural stability, since the cured foam will have flexible properties, thus allowing the substrate to be flexible in the case of an impact from the bottom.

[0051] According to the eleventh aspect, the substrate may further include at least one flange, which is disposed at least on one side of the substrate. The term "flange" refers to a flat protruding edge or collar that is generally used to facilitate the connection, reinforcement, alignment, or sealing of components. The flange can be configured as a mating counterpart to a part of the housing of the battery system to allow the flange and the part of the housing to fit closely together to prevent the foam injected into the battery system during foam overmolding from passing through the contact area between the substrate and the housing.

[0052] The present invention also discloses a battery system. The battery system includes a substrate as claimed before and hereinafter in this document, and a plurality of energy storage units disposed on the substrate. The plurality of energy storage units are supported by the substrate and positioned in a third direction.

[0053] According to the twelfth aspect, each of the plurality of energy storage units may include a vent burst disc. The vent burst disc of each of the plurality of energy storage units can face the substrate.

[0054] The term "venting rupture disc" refers to a safety feature designed to release excess pressure within an energy storage unit of multiple energy storage units. The venting rupture disc can include a thin pressure-sensitive membrane that ruptures if the internal pressure of (some of) the energy storage units among the multiple energy storage units reaches a dangerous level, thereby preventing potential hazards such as overcharging or thermal runaway. This controlled venting of gas from (some of) the energy storage units among the multiple energy storage units helps protect the battery system from damage or explosion. The venting gas passing through the venting rupture disc can further penetrate the wall of the channel of the substrate located below the corresponding venting rupture disc. When necessary, the venting gas passing through the venting rupture disc can also penetrate the cured foam arranged between the venting rupture disc and the wall of the channel. Thus, the venting gas can be guided away through the channel without affecting (some of) the other energy storage units among the multiple energy storage units.

[0055] According to the thirteenth aspect, the battery system can further include foam between at least one main surface of the substrate and at least one of the multiple energy storage units. The foam arranged between at least one main surface of the substrate and at least one of the multiple energy storage units is located below at least one of the multiple energy storage units, thus increasing the amount of the surface area of at least one of the multiple energy storage units encapsulated by the foam. Therefore, both the mechanical stability and rigidity of the battery system and the protection of at least one of the multiple energy storage units are enhanced.

[0056] According to the fourteenth aspect, the battery system can further include a housing and foam within at least one open volume of the substrate. The term "housing" can also be referred to as an enclosure or a case, and preferably refers to a protective container or casing that surrounds some or all of the components of the battery system. The housing provides physical protection for the internal components and typically incorporates features such as insulation, venting, and / or sealing to ensure the safe and efficient operation of the battery system. The housing can also protect the battery system from exposure to water and moisture. The foam within at least one open volume allows for reducing the vibration transmitted from the housing to the substrate and the energy storage units.

[0057] This document also discloses a vehicle. The vehicle includes a battery system as claimed before and hereinafter in this document. The vehicle can be a battery electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV), a hybrid electric vehicle (HEV), or a fuel cell electric vehicle (FCEV), and the battery system can be used as a traction battery.

[0058] Advantageous aspects and / or embodiments of the present disclosure are the subject matter of the dependent claims. Any and all combinations of at least two features disclosed in the specification, claims, and / or drawings fall within the scope of the present disclosure. Naturally, the explanations given in connection with the substrate equivalently relate to the battery system and / or vehicle according to the present disclosure, without redundantly referring to them in their context. In particular, linguistically common rephrasings and / or similar substitutions of the corresponding terms within the scope of common linguistic practice, especially using synonyms supported by generally recognized linguistic literature, are of course included in the presently disclosed content without explicitly mentioning each variation.

[0059] All aspects and / or embodiments as described above can be combined by those skilled in the art in any way they deem appropriate. Other possible embodiments of the present invention also include combinations of any features or aspects and / or embodiments described above or below for exemplary aspects and / or embodiments that are not explicitly mentioned. In such cases, those skilled in the art will also add the respective aspects as improvements or supplements to the corresponding basic forms of the present invention.

[0060] The "a" in this case is not necessarily to be understood as strictly limiting to one element. On the contrary, multiple elements can also be provided, such as, for example, two, three, or more. Any other numbers used herein should not be understood as having the effect of exactly limiting the number of elements specified. On the contrary, numerical deviations up and down are possible, unless otherwise indicated. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 A perspective view showing a first embodiment of the substrate.

[0062] Figure 2 A perspective view showing a second embodiment of the substrate.

[0063] Figure 3 A cross-sectional view showing a first embodiment of the battery system.

[0064] Figure 4 A perspective view showing a second embodiment of the battery system.

[0065] Figure 5 A perspective view showing a third embodiment of the substrate.

[0066] Figure 6 A perspective view showing a fourth embodiment of the substrate.

[0067] Figure 7 A perspective view showing a fifth embodiment of the substrate.

[0068] Figure 8A perspective view showing a sixth embodiment of a substrate.

[0069] Figure 9 A perspective view showing a seventh embodiment of a substrate.

[0070] Figure 10 A perspective view showing an eighth embodiment of a substrate.

[0071] Figure 11 A perspective view showing a ninth embodiment of a substrate.

[0072] Figure 12 A perspective view showing a tenth embodiment of a substrate.

[0073] Figure 13 A perspective view showing an eleventh embodiment of a substrate.

[0074] Figure 14 A cross-sectional view showing a third embodiment of a battery system.

[0075] Figure 15 A cross-sectional view showing a twelfth embodiment of a substrate. Detailed Description

[0076] The present invention will now be described based on the accompanying drawings. It should be understood that the aspects and / or embodiments of the present invention described herein are merely examples and do not limit the scope of protection of the claims in any way. The present invention is defined by the claims and their equivalents. It should be understood that the features of one aspect or embodiment of the present invention can be combined with the features of different aspects or aspects and / or embodiments of the present invention.

[0077] Unless otherwise indicated to the contrary, the same or functionally similar elements are given the same reference numerals in the drawings. It should also be noted that the illustrations in the drawings are not necessarily drawn to actual scale.

[0078] Figure 1 A perspective view showing a first embodiment of a substrate 10. The substrate includes a base body 20 having a rectangular plate shape that extends substantially in a first direction D1 and a second direction D2. The second direction D2 is perpendicular to the first direction D1. The substrate 10 has a bottom surface 22 facing away from a third direction D3. The third direction D3 is perpendicular to the first direction D1 and perpendicular to the second direction D2.

[0079] The substrate 10 further includes six channels 30 that extend substantially in a first direction D1. The number of channels 30 can vary. These channels 30 are arranged parallel to each other and are evenly distributed along a second direction D2, where each two adjacent channels among the channels 30 are spaced apart from each other in the second direction D2. The channels 30 include a main volume 40 that extends substantially in the first direction D1 and a wall 80 that defines or encloses the main volume 40. The channels 30 are integrally formed with the substrate 20 such that the substrate 20 forms a part of the wall 80 of the channels 30. Alternatively or additionally, the channels 30 can be separate components attached to the substrate 20.

[0080] The channels 30 have a hollow cross-section that has a trapezoidal shape with rounded edges. All six channels 30 are designed similarly. The substrate 10 can alternatively or additionally include channels 30 of different shapes and / or different sizes.

[0081] The channels 30 further include a support structure 50. The support structure 50 is arranged at a first side S1 of the channels 30. The first side S1 is located at an outer surface of the wall 80 of the channels 30, and the outer surface and the first side S1 face substantially in the first direction D1.

[0082] The support structure 50 includes a plurality of first contact surfaces 52 and a plurality of main surfaces 56. The plurality of first contact surfaces 52 have the shape of a spherical segment. The plurality of main surfaces 56 have a flat shape and are defined as the surface of the channels 30 at the first side S1 that does not form the plurality of first contact surfaces 52. The plurality of first contact surfaces 52 extend significantly further in a third direction D3 than the plurality of main surfaces 56.

[0083] The plurality of first contact surfaces 52 and the plurality of main surfaces 56 are arranged in a repeating pattern, where one of the plurality of first contact surfaces 52 is arranged adjacent to one of the plurality of main surfaces 56 in the first direction D1. Thus, the plurality of first contact surfaces 52 and the plurality of main surfaces 56 are alternately arranged in the first direction D1. The offset of the repeating pattern of two adjacent channels 30 among the channels 30 is half of the diameter of the energy storage unit 110 to be arranged on the substrate 10.

[0084] The plurality of first contact surfaces 52 and the plurality of main surfaces 56 are integrally provided with the wall 80 of the channels 30 and thus form part of the outer surface of the channels 30.

[0085] A plurality of voids 58 are respectively formed between two adjacent first contact surfaces 52 among the plurality of first contact surfaces 52 disposed on one of the channels 30. An open volume 60 is formed between two adjacent channels 30. The open volume 60 extends substantially in a first direction D1 and is defined or surrounded by the walls 80 of two adjacent channels 30 in the channels 30 and the substrate 20. The open volume 60 is not limited to a third direction D3.

[0086] The substrate 10 has a first end E1 and a second end E2. The first end E1 and the second end E2 are located at opposite ends of the substrate 10 in the first direction D1. The channel 30 further includes openings 70 at the first end E1 and the second end E2. Accordingly, the main volume 40 is not limited to the first direction D1 and the direction opposite to the first direction D1.

[0087] The substrate 10 further includes two flanges 90 that extend in the first direction and are located at opposite ends of the substrate 10 in a second direction D2. The two flanges 90 have the form of a flat rectangular extension of the substrate 20.

[0088] Figure 2 A perspective view of a second embodiment of the substrate 10 is shown. In addition to the plurality of first contact surfaces 52, the support structure 50 further includes a plurality of second contact surfaces 54 and a plurality of third contact surfaces 59. The plurality of first contact surfaces 52 are arranged in rows extending in the first direction D1. Two adjacent first contact surfaces among the plurality of first contact surfaces 52 are arranged offset from each other, thereby forming corresponding voids 58. The plurality of second contact surfaces 54 are arranged in rows extending in the first direction D1. Two adjacent second contact surfaces among the plurality of second contact surfaces 54 are arranged offset from each other, thereby forming corresponding voids 58. The plurality of third contact surfaces 59 are arranged in rows extending along the first direction D1. Two adjacent third contact surfaces among the plurality of third contact surfaces 59 are arranged offset from each other, thereby forming corresponding voids 58.

[0089] The rows of the plurality of first contact surfaces 52, the rows of the plurality of second contact surfaces 54, and the rows of the plurality of third contact surfaces 59 are respectively offset from each other in the second direction D2. The row of the plurality of second contact surfaces 54 is centered between the row of the plurality of first contact surfaces 52 and the row of the plurality of third contact surfaces 59 in the second direction D2.

[0090] The plurality of first contact surfaces 52, the plurality of second contact surfaces 54, and the plurality of third contact surfaces 59 have a rectangular shape that extends substantially in the first direction D1. The plurality of first contact surfaces 52 and the plurality of third contact surfaces 59 are of the same size. The plurality of second contact surfaces 54 have a smaller extension in the first direction D1 compared to the plurality of first contact surfaces 52 and the plurality of third contact surfaces 59. The gap 58 between two adjacent first contact surfaces among the plurality of first contact surfaces 52 has the same size as the gap 58 between two adjacent third contact surfaces among the plurality of third contact surfaces 59. The gap 58 between two adjacent second contact surfaces among the plurality of second contact surfaces 54 has a greater extension in the first direction D1 compared to the gap 58 between two adjacent first contact surfaces among the plurality of first contact surfaces 52 and the gap 58 between two adjacent third contact surfaces among the plurality of third contact surfaces 59.

[0091] The plurality of first contact surfaces 52 and the main surface 56 or the corresponding gaps 58 are arranged in a repeating pattern, and the plurality of third contact surfaces 59 and the main surface 56 or the corresponding gaps 58 are also arranged in a repeating pattern. The rows or repeating patterns of the plurality of first contact surfaces 52 are offset in the first direction D1 with respect to the rows or repeating patterns of the plurality of third contact surfaces 59.

[0092] Figure 3 A cross-sectional view of a first embodiment of the battery system 100 is shown. The battery system 100 includes a substrate 10 according to the first embodiment and taken along Figure 1 section line A-A as shown. The battery system 100 further includes a housing 120 that encloses the components of the battery system 100. The substrate 10 is disposed at the inner surface of the housing 120.

[0093] The battery system 100 further includes a plurality of energy storage units 110 in the form of cylindrical battery cells, Figure 3 only one of which is shown. The energy storage unit 110 is disposed on top of one of the plurality of first contact surfaces 52 in one of the channels 30 of the substrate 10. The energy storage unit 110 is centered with respect to the corresponding first contact surface 52. The energy storage unit 110 includes an exhaust rupture disk 112 that is disposed at the bottom surface of the energy storage unit 110 and at a central position above the corresponding first contact surface 52.

[0094] The battery system 100 further includes a cured foam 130 between the substrate 10 and the energy storage unit 110. The spherical frustum shape of the plurality of first contact surfaces 52 provides a free volume between the respective channels 30 and the energy storage unit 110, and this free volume is occupied by the cured foam. The plurality of main surfaces 56 also provide a free volume between the respective channels 30 and the energy storage unit 110, and this free volume is occupied by the cured foam. The main volume 40 of the channels 30 is empty and does not contain any cured foam.

[0095] Figure 4 A perspective view showing a second embodiment of the battery system 100 is presented. The battery system 100 includes a substrate 10 and a housing 120 according to the ninth embodiment described in Figure 11 . The battery system 100 further includes a plurality of energy storage units 110 arranged on the substrate 10.

[0096] The housing 120 includes at least one outlet 122. The outlet 122 is fluidly connected to the channel 30 of the substrate 10. The outlet 122 is used to safely direct the exhaust gas to the outside of the housing 120, and these exhaust gases come from some of the plurality of energy storage devices 110 passing through the channel 30.

[0097] Figure 5 A perspective view showing a third embodiment of the substrate 10 is presented. The support structure 50 includes a plurality of first contact surfaces 52, a plurality of second contact surfaces 54, and a plurality of third contact surfaces 59. The plurality of first contact surfaces 52 are arranged in rows extending in the first direction D1. Two adjacent first contact surfaces among the plurality of first contact surfaces are arranged offset from each other, thereby forming corresponding voids 58. The plurality of second contact surfaces 54 are arranged in rows extending in the first direction D1. Two adjacent second contact surfaces among the plurality of second contact surfaces are arranged offset from each other, thereby forming corresponding voids 58. The plurality of third contact surfaces 59 are arranged in rows extending in the first direction D1. Two adjacent third contact surfaces among the plurality of third contact surfaces are arranged offset from each other, thereby forming corresponding voids 58.

[0098] The rows of the plurality of first contact surfaces 52, the rows of the plurality of second contact surfaces 54, and the rows of the plurality of third contact surfaces 59 are offset relative to each other in the second direction D2. The row of the plurality of second contact surfaces 54 is centered between the row of the plurality of first contact surfaces 52 and the row of the plurality of third contact surfaces 59 along the second direction D2.

[0099] The plurality of first contact surfaces 52, the plurality of second contact surfaces 54, and the plurality of third contact surfaces 59 have a rectangular shape that extends substantially in the first direction D1. The plurality of first contact surfaces 52 and the plurality of third contact surfaces 59 are of the same size. The plurality of second contact surfaces 54 have a smaller extension in the first direction D1 compared to the plurality of first contact surfaces 52 and the plurality of third contact surfaces 59. The gap 58 between two adjacent first contact surfaces among the plurality of first contact surfaces 52 has the same size as the gap 58 between two adjacent third contact surfaces among the plurality of third contact surfaces 59. The gap 58 between two adjacent second contact surfaces among the plurality of second contact surfaces 54 has a greater extension in the first direction D1 compared to the gap 58 between two adjacent first contact surfaces among the plurality of first contact surfaces 52 and the gap 58 between two adjacent third contact surfaces among the plurality of third contact surfaces 59.

[0100] The plurality of first contact surfaces 52 and the main surface 56 or the corresponding gaps 58 are arranged in a repeating pattern, and the plurality of third contact surfaces 59 and the main surface 56 or the corresponding gaps 58 are also arranged in a repeating pattern. The rows or repeating patterns of the plurality of first contact surfaces 52 are not offset in the first direction D1 relative to the rows or repeating patterns of the plurality of third contact surfaces 59. The rows or repeating patterns of the plurality of second contact surfaces 54 are offset in the first direction D1 relative to the rows or repeating patterns of the plurality of first contact surfaces 52.

[0101] Figure 6 A perspective view of a fourth embodiment of the substrate 10 is shown. The corresponding support structure 50 of each channel 30 includes only one first contact surface 52, one second contact surface 54, and one main surface 56. Each of the first contact surface 52, the second contact surface 54, and the main surface 56 extends continuously from the first end E1 to the second end E2 of the substrate 10 in the first direction D1.

[0102] The arrangement and continuous design of the first contact surface 52, the second contact surface 54, and the main surface 56 allow not only the use of a vacuum forming process to manufacture the substrate 10, but also the use of a cost-effective extrusion process having an extrusion direction along the first direction 10 to manufacture the substrate 10.

[0103] Figure 7 A perspective view of a fifth embodiment of the substrate 10 is shown. The substrate 10 according to the fifth embodiment is similar to Figure 5 the substrate 10 according to the third embodiment as shown, except that the substrate 10 according to the fifth embodiment does not include any second contact surfaces 54.

[0104] Figure 8 A perspective view of a sixth embodiment of the substrate 10 is shown. The substrate 10 according to the sixth embodiment is similar to Figure 2The substrate 10 according to the second embodiment shown, except that the substrate 10 according to the sixth embodiment does not include any second contact surfaces 54.

[0105] Figure 9 A perspective view showing a seventh embodiment of the substrate 10 is shown. The corresponding support structures 50 of the channels 30 of the substrate 10 include a plurality of first contact surfaces 52 and a plurality of main surfaces 56. The plurality of first contact surfaces 52 have a trapezoidal shape and extend substantially in a plane perpendicular to the third direction D3 in a direction inclined at 45 degrees to the first direction D1 and inclined at 45 degrees to the second direction D2.

[0106] Figure 10 A perspective view showing an eighth embodiment of the substrate 10 is shown. The corresponding support structures 50 of the channels 30 of the substrate 10 include a plurality of first contact surfaces 52 and a plurality of main surfaces 56. The plurality of first contact surfaces 52 have an arrow-like shape and point in the first direction D1.

[0107] Figure 11 A perspective view showing a ninth embodiment of the substrate 10 is shown. The corresponding support structures 50 of the channels 30 of the substrate 10 include a plurality of first contact surfaces 52, a plurality of second contact surfaces 54, a plurality of third contact surfaces 59 and a plurality of main surfaces 56. The plurality of first contact surfaces 52 and the plurality of third contact surfaces 59 have a triangular shape, and the plurality of second contact surfaces 54 have a square shape.

[0108] Figure 12 A perspective view showing a tenth embodiment of the substrate 10 is shown. The substrate 10 according to the tenth embodiment is similar to Figure 11 the substrate 10 according to the ninth embodiment shown, except that the substrate 10 according to the tenth embodiment does not include any first contact surfaces 52 and any third contact surfaces 59.

[0109] Figure 13 A perspective view showing an eleventh embodiment of the substrate 10 is shown. The corresponding support structures 50 of the channels 30 of the substrate 10 include a plurality of first contact surfaces 52 and a plurality of main surfaces 56. The plurality of main surfaces 56 have an inverted spherical frustum shape.

[0110] Figure 14 A cross-sectional view showing a third embodiment of the battery system 100 is shown. The battery system 100 includes the substrate 10 according to the second embodiment and shown along the Figure 2 section line B-B. The battery system 10 also includes a housing 120 surrounding the components of the battery system 100. The flange 90 of the substrate 10 contacts the mating corresponding surface of the housing 120. Thus, it is prevented that the foam 130 of the battery system 100 and the foam 130 arranged within the housing 120 leak to the outside of the housing 120 at the contact between the flange 90 and the housing 120.

[0111] The battery system 10 can also include a sealing material disposed between the flange 90 and the housing 120 in the contact area between the flange 90 and the housing to enhance the tightness of the battery system 100.

[0112] Figure 15 A cross-sectional view of a twelfth embodiment of the substrate 10 is shown. The substrate 10 according to the twelfth embodiment is similar to Figure 2 the substrate 10 according to the second embodiment shown, except that the open volume 60 extends in a third direction D3 below the bottom surface 22 of the base body 20. The open volume 60 is filled with a cured foam 130 that contacts a portion of the housing 120 of the battery system 100, while the bottom surface 22 of the substrate 10 does not contact the housing 120. List of Reference Numerals 10 Substrate 20 Base Body 22 Bottom Surface 30 Channel 40 Main Volume 50 Support Structure 52 First Contact Surface 54 Second Contact Surface 56 Main Surface 58 Void 59 Third Contact Surface 60 Open Volume 70 Opening 80 Wall 90 Flange 100 Battery System 110 Energy Storage Unit 112 Vent Burst Disc 120 Housing 122 Outlet 124 Inlet 126 Distribution Channel 130 Foam 200 Vehicle D1 First Direction D2 Second Direction D3 Third Direction E1 First End E2 Second End S1 First Side

Claims

1. A substrate (10) for a battery system (100), the substrate (10) comprising: A substrate (20); as well as At least two channels (30), the at least two channels extending in a first direction (D1) and offset from each other in a second direction (D2), preferably the second direction being perpendicular to the first direction (D1), wherein The at least two channels (30) include a main volume (40) and a support structure (50); The support structure (50) is arranged at a first side (S1) of the main volume (40), and the support structure comprises at least one first contact surface (52) capable of contacting an energy storage unit (110) and at least one main surface (56); The at least one first contact surface (52) is offset relative to the at least one main surface (56) in a third direction (D3), wherein the third direction (D3) is perpendicular to the first direction (D1) and the second direction (D2).

2. The substrate (10) according to claim 1, wherein: The at least two channels (30) are spaced apart in the second direction (D2) to form at least one open volume (60), and the at least one open volume (60) extends in the first direction (D1).

3. The substrate (10) according to claim 1 or 2, wherein: The substrate (10) has a first end (E1) and a second end (E2), wherein the first end (E1) and the second end (E2) are offset from each other in the first direction (D1), and the at least two channels (30) have openings (70) only at the first end (E1) and / or the second end (E2).

4. The substrate (10) according to any one of the preceding claims, wherein The at least one first contact surface (52) and the at least one major surface (56) are arranged in a repeating pattern.

5. The substrate (10) according to any one of the preceding claims, wherein The support structure (50) further includes at least one second contact surface (54) capable of contacting an energy storage unit.

6. The substrate (10) according to claim 5, wherein: The at least one first contact surface (52) and the at least one second contact surface (54) are offset from each other in the first direction (D1) and / or in the second direction (D2).

7. The substrate (10) according to claim 6, wherein: The at least one second contact surface (54) and the at least one major surface (56) are arranged in a repeating pattern that is offset in the first direction (D1) relative to a repeating pattern of the at least one first contact surface (52) and the at least one major surface (56).

8. The substrate (10) according to any one of the preceding claims, further comprising a plurality of first contact surfaces (52), wherein the plurality of first contact surfaces (52) have a rectangular shape extending in the first direction (D1).

9. The substrate (10) according to claim 8, wherein: In the first direction (D1), adjacent first contact surfaces among the plurality of first contact surfaces (52) are separated by gaps (58).

10. The substrate (10) according to claim 9, wherein: The support structure (50) further comprises a plurality of third contact surfaces (59) capable of contacting the energy storage unit and a plurality of second contact surfaces (54) capable of contacting the energy storage unit; The plurality of second contact surfaces (54) and the plurality of third contact surfaces (59) have a rectangular shape extending in the first direction (D1); The plurality of first contact surfaces (52) are arranged in a row extending in the first direction (D1), the plurality of second contact surfaces (54) are arranged in a row extending in the first direction (D1), and the plurality of third contact surfaces (59) are arranged in a row extending in the first direction (D1); The row of the plurality of first contact surfaces (52), the row of the plurality of second contact surfaces (54), and the row of the plurality of third contact surfaces (59) are offset from each other in the second direction (D2); In the first direction (D1), adjacent second contact surfaces among the plurality of second contact surfaces (54) are separated by gaps (58), and in the first direction (D1), adjacent second contact surfaces among the plurality of third contact surfaces (59) are separated by gaps (58); The plurality of third contact surfaces (59) and the at least one main surface (56) are arranged in a repeating pattern, and the repeating pattern is offset in the first direction (D1) relative to the repeating pattern of the plurality of first contact surfaces (52) and the at least one main surface (56) and relative to the repeating pattern of the plurality of second contact surfaces (54) and the at least one main surface (56).

11. The substrate (10) according to any one of the preceding claims, wherein The at least one open volume (60) extends below the bottom surface (22) of the base (20) in the third direction (D3), such that the at least one open volume (60) extends further than the at least two channels (30) in the third direction (D3).

12. The base plate (10) according to any one of the preceding claims, further comprising at least one flange (90), the at least one flange being arranged at least at one side of the base plate (10).

13. A battery system (100) for a vehicle (200), the battery system (100) comprising: The substrate (10) according to any one of claims 1 to 12; as well as A plurality of energy storage units (110) are arranged on the substrate (10).

14. The battery system (100) according to claim 13, wherein: Each energy storage unit of the plurality of energy storage units (110) includes a venting burst disc (112); and The exhaust bursting disc (112) of each energy storage unit in the plurality of energy storage units (110) faces the base plate (10).

15. The battery system (100) according to claim 11 or 14, further comprising a foam (130) between at least one major surface (56) of the substrate (10) and at least one energy storage cell of the plurality of energy storage cells (110).

16. The battery system (100) according to any one of claims 11 to 15, further comprising: Housing (120); as well as A foam (130) is provided in at least one open volume (60) of the substrate (10).

17. A vehicle (200) comprising the battery system (100) according to claims 11-16.

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