Super beam design for cylindrical battery cell assembly

Abstract

A rechargeable energy storage system includes a housing including a tray and a sidewall structure. A plurality of beam assemblies extend in parallel through the housing, each of the plurality of beam assemblies including a bottom cover having a base plate and a pair of parallel ribs extending from the base plate. The coolant channel plate is sandwiched between a pair of corrugated plates having a first end disposed between a pair of parallel ribs of the bottom cover. The coolant channel plate is connected to a coolant source. A plurality of battery cells are disposed in the housing and in contact with the corrugated plates of adjacent beam assemblies.

Description

Technical Field

[0001] The present disclosure relates to a cooling beam design for battery cell assemblies. Background Art

[0002] The information provided in this section is for the purpose of generally introducing the background of the present disclosure. To the extent described in this section, the work of the currently named inventors and aspects that may not constitute prior art descriptions at the time of filing are neither expressly nor implicitly admitted to be prior art against the present disclosure.

[0003] Strips are commonly used in cylindrical battery cell assemblies to facilitate battery cell cooling. However, strips have several existing problems. First, they lack structural rigidity. Second, they need to be attached to the battery cell wall during the assembly process because they cannot stand upright independently. Third, due to the predetermined position of the battery cell bracket on the battery cell during the assembly process, the strips do not establish tight contact with the battery cell on both sides, which may affect the cooling performance. Summary of the Invention

[0004] A rechargeable energy storage system includes a housing that includes a tray and a sidewall structure. A plurality of beam assemblies extend parallelly through the housing, and each of the plurality of beam assemblies includes a bottom cover having a base plate and a pair of parallel ribs extending from the base plate. A coolant channel plate is sandwiched between a pair of corrugated plates, and the corrugated plates have a first end disposed between the pair of parallel ribs of the bottom cover. The coolant channel plate is connected to a coolant source. A plurality of battery cells are disposed in the housing and are in contact with the corrugated plates of adjacent beam assemblies.

[0005] According to another aspect, a top cover includes a base plate and a pair of parallel ribs extending from the base plate, the top cover is disposed above the second end of the corrugated plate, and the pair of parallel ribs are located on opposite sides of the pair of corrugated plates.

[0006] According to another aspect, an end of the top cover is connected to the sidewall structure.

[0007] According to another aspect, the thickness of the pair of corrugated plates ranges from 1 mm to 1.5 mm.

[0008] According to another aspect, the thickness of the coolant channel plate ranges from 0.3 mm to 0.6 mm.

[0009] According to another aspect, the bottom covers of the plurality of beam assemblies are fixed to the tray.

[0010] According to another aspect, one of an adhesive or a foam material is disposed between the pair of parallel ribs of the bottom cover.

[0011] According to another aspect, the bottom cover is made of extruded aluminum.

[0012] According to another aspect, the bottom cover is made of a composite material.

[0013] According to another aspect, a plurality of battery cells are supported on one of the pair of ribs of adjacent beam assemblies.

[0014] According to another aspect, a ventilation passage is provided between the bottom covers of adjacent beam assemblies.

[0015] According to another aspect, a plurality of beam assemblies include a pair of coolant channel plates sandwiched between the pair of corrugated plates.

[0016] According to another aspect, the coolant channel plates are made of an elastic material.

[0017] According to another aspect, the coolant channel plates are made of one of a composite material and a polymeric material.

[0018] According to another aspect, the pair of corrugated plates are made of metal.

[0019] According to another aspect, the pair of corrugated plates are made of one of a composite material and a polymeric material, and the coolant channel plates are made of metal.

[0020] According to another aspect, coolant connectors communicate with each of the coolant channel plates.

[0021] According to another aspect, the coolant connectors of each of the coolant channel plates are connected to a coolant source.

[0022] According to another aspect, the coolant connectors of each of the coolant channel plates are connected to the coolant connectors of adjacent beam assemblies.

[0023] According to another aspect, the ends of the bottom covers of the plurality of beam assemblies are connected to a sidewall structure.

[0024] The present invention provides the following technical solutions:

[0025] 1. A rechargeable energy storage system, comprising:

[0026] A housing including a tray and a sidewall structure;

[0027] A plurality of beam assemblies extending parallel through the housing, each of the plurality of beam assemblies including a bottom cover having a base plate and a pair of parallel ribs extending from the base plate, a coolant channel plate sandwiched between a pair of corrugated plates, the corrugated plates having a first end disposed between the pair of parallel ribs of the bottom cover, wherein the coolant channel plate is connected to a coolant source; and

[0028] A plurality of battery cells disposed within the housing and in contact with the corrugated plates of adjacent beam assemblies.

[0029] 2. The rechargeable energy storage system according to Solution 1 further includes a top cover having a base plate and a pair of parallel ribs extending from the base plate. The top cover is disposed above the second end of the corrugated plate, and the pair of parallel ribs are located on opposite sides of the pair of corrugated plates.

[0030] 3. The rechargeable energy storage system according to Solution 2, wherein an end of the top cover is connected to the side wall structure.

[0031] 4. The rechargeable energy storage system according to Solution 1, wherein the thickness range of the pair of corrugated plates is from 1 mm to 1.5 mm.

[0032] 5. The rechargeable energy storage system according to Solution 1, wherein the thickness range of the coolant channel plate is from 0.3 mm to 0.6 mm.

[0033] 6. The rechargeable energy storage system according to Solution 1, wherein the bottom cover of the plurality of beam assemblies is fixed to the tray.

[0034] 7. The rechargeable energy storage system according to Solution 1 further includes one of an adhesive or a foam material located between the pair of parallel ribs of the bottom cover.

[0035] 8. The rechargeable energy storage system according to Solution 1, wherein the bottom cover is made of extruded aluminum.

[0036] 9. The rechargeable energy storage system according to Solution 1, wherein the bottom cover is made of a composite material.

[0037] 10. The rechargeable energy storage system according to Solution 1, wherein the plurality of battery cells are supported on one of the pair of ribs of adjacent beam assemblies.

[0038] 11. The rechargeable energy storage system according to Solution 1 further includes a ventilation channel disposed between the bottom covers of adjacent beam assemblies.

[0039] 12. The rechargeable energy storage system according to Solution 1, wherein the plurality of beam assemblies include a pair of coolant channel plates sandwiched between the pair of corrugated plates.

[0040] 13. The rechargeable energy storage system according to Solution 1, wherein the coolant channel plate is made of an elastic material.

[0041] 14. The rechargeable energy storage system according to Solution 1, wherein the pair of corrugated plates are made of metal.

[0042] 15. The rechargeable energy storage system according to Scheme 1 further includes coolant connectors communicating with each coolant channel plate.

[0043] 16. The rechargeable energy storage system according to Scheme 15, wherein the coolant connectors of each coolant channel plate are connected to a coolant source.

[0044] 17. The rechargeable energy storage system according to Scheme 15, wherein the coolant connectors of each coolant channel plate are connected to the coolant connectors of an adjacent beam assembly.

[0045] 18. The rechargeable energy storage system according to Scheme 1, wherein the ends of the bottom covers of the plurality of beam assemblies are connected to the side wall structure.

[0046] 19. A rechargeable energy storage system includes:

[0047] A housing including a tray and a side wall structure;

[0048] A plurality of beam assemblies extending parallel through the housing, each of the plurality of beam assemblies including a bottom cover having a base plate and a pair of parallel ribs extending from the base plate, a coolant channel plate being sandwiched between a pair of corrugated plates, the corrugated plates having a first end disposed between the pair of parallel ribs of the bottom cover, wherein the coolant channel plate is connected to a coolant source;

[0049] A plurality of battery cells disposed in the housing and in contact with the corrugated plates of adjacent beam assemblies, wherein the plurality of battery cells are supported on one of a pair of ribs of adjacent beam assemblies; and

[0050] Coolant connectors communicating with each coolant channel plate,

[0051] wherein the coolant connectors of each coolant channel plate are connected to a coolant source.

[0052] 20. The rechargeable energy storage system according to Scheme 19, wherein the coolant channel plate is made of an elastic material.

[0053] Additional application areas of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The present disclosure will be more fully understood from the detailed description and the drawings, wherein:

[0055] Figure 1 is a perspective view of a part of a battery cell assembly having a beam-type battery separator according to the principles of the present disclosure;

[0056] Figure 2is a perspective view of a beam assembly in accordance with the principles of the present disclosure;

[0057] Figure 3 is an exploded isometric view of a beam assembly in accordance with the principles of the present disclosure;

[0058] Figure 4 is an end plan view of battery cells separated by a super beam assembly in accordance with the principles of the present disclosure;

[0059] Figure 5 is a perspective view of multiple rows of battery cells separated by a beam assembly in accordance with the principles of the present disclosure; and

[0060] Figure 6 is a perspective view of multiple rows of battery cells separated by a beam assembly including an optional top cover in accordance with the principles of the present disclosure.

[0061] In the figures, reference numerals may be reused to identify like and / or identical elements. DETAILED DESCRIPTION

[0062] Reference Figure 1 , there is shown a portion of a rechargeable energy storage system 10 that includes a wall structure 12 (showing a portion thereof) surrounding a tray 14, on which a plurality of battery cells 18 are arranged. In accordance with the principles of the present disclosure, the battery cells 18 are arranged in multiple rows 20, each row 20 being separated by a beam assembly 22.

[0063] Reference Figure 3 , each beam assembly 22 includes a bottom cover 24, an optional top cover 26 (see Figure 6 ), a pair of corrugated panels 28, and a pair of coolant channel plates 30. The curvature of the corrugated panels 28 is designed to conform to the outer wall of the cylindrical battery cells 18 after assembly. The bottom cover 24 of the beam assembly includes a base plate 24a and a pair of spaced-apart ribs 24b extending from the base plate 24a. The bottom cover 24 may be formed of an extruded aluminum piece or a composite material. The bottom cover 24 holds the pair of corrugated panels 28 and the pair of coolant channel plates 30 in place. Foam or an adhesive material may be dispensed into the gap between the pair of spaced-apart ribs 24b of the bottom cover 24 to further secure the corrugated panels 28 and the coolant channel plates 30. The bottom of the bottom cover 24 is fixed to the battery tray 14 by welding or adhesive bonding. If desired, the bottom cover 24 may be integrated into the design of the bottom shear plate. The bottom cover 24 provides structural rigidity to protect the battery cells 18 from side and bottom impacts. Additionally, the bottom cover 24 serves as a platform on which the battery cells 18 are placed during assembly.

[0064] The pair of coolant channel plates 30 has the ability to be compressed along the normal direction of the beam assembly 22, thereby providing elasticity during both assembly and battery use. Cooling channels are formed between the panel 28 and its corresponding coolant channel plate 30, such that a cooling medium such as coolant can flow into and out of the channels to carry away heat from the panel 28 in contact with the battery cell 18 during cooling and bring heat during heating. Although the main function is to provide cooling / heating, the secondary function of the pair of coolant channel plates 30 is to establish tight contact between the corrugated panel 28 and the wall of the battery cell 18, thereby optimizing the cooling effect. The coolant channel plates 30 can be made of aluminum material, polymer material, or composite material. Alternatively, a combination of materials can be employed, where a pair of corrugated panels 28 is made of composite material or polymer material and the coolant channel plates are made of metallic material. The corrugated panel 28 can be stamped or extruded, while the coolant channel plates can be stamped or otherwise formed from laminated materials. The coolant channel plates 30 and the corrugated panel 28 can be joined together using brazing, welding, or adhesive bonding methods.

[0065] The bottom cover 24 and the top cover 26 are designed to contact the sidewalls 12 of the battery tray at their respective ends to carry / transfer loads. Both the corrugated plate 28 and the coolant channel plates 30 have shortened lengths to avoid participating in any load-bearing function, in order to protect the cooling channels and connections. The coolant channel plates 30 include coolant connectors 32, which are located at both ends of the coolant channel plates 30, either on the sides or at the ends. The coolant connectors 32 of adjacent beam assemblies 22 can be connected to each other, and the coolant connectors can all be connected to a coolant source 33. The height of the beam assembly 22 is specifically designed to leave space at the top for installing busbars or other requirements. The top cover 26 (see Figure 6 ) is optional and is used to enhance the structural stiffness and limit the vertical movement of the battery cell 18. The top cover 26 can be composed of an extruded aluminum piece or a composite material and has the same shape as the bottom cover 24. The top cover 26 tightly encloses a pair of corrugated plates 28 and a pair of coolant channel plates 30 from the top, and an adhesive can be used to ensure a firm connection between the pair of corrugated plates 28, the pair of coolant channel plates 30, and the top cover 26. Additionally, the top cover 26 can be connected to the top shear plate of the battery module housing using extended flanges and mechanical bolts.

[0066] When assembling the beam assembly 22 and the cylindrical battery cell 18 into a battery pack, the concept of modular components can be adopted. The beam assembly 22 is pre-assembled into a slightly compressed temporary structure and then inserted into the battery tray 14. Laser spot welding can be performed to fix the beam position by connecting the bottom cover 24 to the tray. Another option is to bond the bottom cover 24 to the tray 14. The ends of the bottom cover 24 and the top cover can be connected to the sidewall structure 12 by brackets and / or other fasteners. This ensures that once the coolant is filled by a coolant source, the battery cell 18 is in close contact with the beam assembly 22. The beam assembly 22 is capable of cell retention, effective cooling, and protection of the cylindrical battery cells 18 in the battery pack. When using a separator plate with ventilation holes at the bottom of the battery cell during assembly to allow the battery cell to exhaust downward, the channels formed between the bottom covers 24 (see Figure 4 ) also serve as an ideal thermal runaway exhaust route.

[0067] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Thus, although the disclosure includes specific examples, the true scope of the disclosure should not be so limited because other modifications will become apparent after studying the drawings, the specification, and the appended claims. It should be understood that one or more steps within a method can be performed in a different order (or concurrently) without changing the principles of the disclosure. Additionally, although each embodiment is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with each other are still within the scope of the disclosure.

[0068] Various terms are used, including "connected", "engaged", "coupled", "adjacent", "next to", "on", "above", "below", and "disposed", to describe the spatial and functional relationships between various elements (e.g., between modules, circuit elements, semiconductor layers, etc.). When the relationship between a first element and a second element is described in the foregoing disclosure, unless explicitly described as "direct", the relationship can be a direct relationship where no other intermediate elements exist between the first element and the second element, but can also be an indirect relationship where one or more intermediate elements (spatially or functionally) exist between the first element and the second element. As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean a logical (A or B or C) using non-exclusive logic "or", and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C".

Claims

1. A rechargeable energy storage system, comprising: A housing including a tray and a sidewall structure; A plurality of beam assemblies extending parallel through the housing, each of the plurality of beam assemblies including a bottom cover having a base plate and a pair of parallel ribs extending from the base plate, a coolant channel plate sandwiched between a pair of corrugated plates, the corrugated plates having a first end disposed between the pair of parallel ribs of the bottom cover, wherein the coolant channel plate is connected to a coolant source; and A plurality of battery cells disposed within the housing and in contact with the corrugated plates of adjacent beam assemblies.

2. The rechargeable energy storage system according to claim 1, further comprising a top cover having a base plate and a pair of parallel ribs extending from the base plate, the top cover being disposed above the second end of the corrugated plates, and the pair of parallel ribs being located on opposite sides of the pair of corrugated plates.

3. The rechargeable energy storage system according to claim 2, wherein, An end of the top cover is connected to the sidewall structure.

4. The rechargeable energy storage system according to claim 1, wherein, The pair of corrugated plates has a thickness in the range of 1 mm to 1.5 mm.

5. The rechargeable energy storage system according to claim 1, wherein, The coolant channel plate has a thickness in the range of 0.3 mm to 0.6 mm.

6. The rechargeable energy storage system according to claim 1, wherein the bottom covers of the plurality of beam assemblies are fixed to the tray.

7. The rechargeable energy storage system according to claim 1, further comprising one of an adhesive or a foam material disposed between the pair of parallel ribs of the bottom cover.

8. The rechargeable energy storage system according to claim 1, wherein the bottom cover is made of extruded aluminum.

9. The rechargeable energy storage system according to claim 1, wherein, The bottom cover is made of a composite material.

10. The rechargeable energy storage system according to claim 1, wherein the plurality of battery cells are supported on one of the pair of ribs of adjacent beam assemblies.

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