Multifunctional side beam assembly for structural battery

Abstract

A vehicle rocker track includes an extrusion molded member configured for mounting on a vehicle equipped with the vehicle rocker track. The extrusion molded member includes a first side, a second side opposite the first side, and upper and lower sides extending between the first and second sides, respectively. The first side extends along a battery cell of a vehicle with the extrusion molded member mounted on the vehicle. The extrusion molded member defines a ventilation chamber. Battery cell vents are formed through the first side. The battery cell vent is configured to fluidly connect the battery cell and the vent chamber with the extrusion molded member mounted at the vehicle. A packaging vent is formed through the lower side. The battery pack vent is configured to fluidly connect the vent chamber at the lower side to an exterior of the vehicle with the extrusion molded member mounted at the vehicle.

Description

[0001] Introduction

[0002] The information provided in this section is for the purpose of generally presenting the context of the present disclosure. The work of the presently named inventors, to the extent it is described in this section, and aspects that may not be eligible as prior art at the time of filing, are neither expressly nor implicitly admitted as prior art against the present disclosure. Technical Field

[0003] The present disclosure generally relates to structural battery assemblies for vehicles, and more particularly, to cell-to-pack (CTP) and cell-to-body (CTB) structural battery assemblies. Specifically, the present disclosure provides a side beam structure for a structural battery assembly that provides longitudinal structural support for the battery assembly and a rocker rail structure for the vehicle. The side beam structure includes one or more first vents and one or more second vents, where the one or more first vents are configured to fluidly couple a plenum chamber of the side beam structure to one or more battery cells of the battery assembly, and the one or more second vents are configured to fluidly couple the plenum chamber to the exterior of the vehicle at a lower side of the side beam structure. Background Art

[0004] Battery-powered vehicles such as electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs) are typically equipped with structural battery packs integrated with the vehicle's chassis or frame. These battery packs generally include multiple battery cells. When a single cell within the battery pack fails (e.g., due to physical impact during a vehicle collision or due to a short circuit), a battery pack thermal runaway situation may occur. During a thermal runaway event, the failure of one battery cell may cause the failure of additional battery cells, such as due to the additional battery cells being exposed to hot gases, flames, and particulates vented from the failed battery cell.

[0005] To reduce the impact of a failed battery cell on additional battery cells within the battery assembly, the side beam structure of the battery assembly includes an extruded member that defines a plenum chamber. A first vent formed through the extruded member is configured to fluidly connect one or more battery cells of the battery assembly to the plenum chamber, and a second vent formed through the extruded member is configured to fluidly connect the plenum chamber to the exterior of the vehicle. Thus, during a thermal runaway of a battery cell, hot gases, flames, and / or particulates vented from the failed battery cell are directed through the first vent and the plenum chamber and out the second vent away from the battery assembly, thereby reducing or eliminating the impact of the failed battery cell on additional battery cells within the assembly. Summary of the Invention

[0006] One aspect of the present disclosure provides a vehicle rocker rail. The vehicle rocker rail includes an extruded member configured to be mounted on a vehicle equipped with the vehicle rocker rail. The extruded member includes a first side, a second side opposite the first side, and upper and lower sides extending between the first side and the second side, respectively. When the extruded member is mounted on the vehicle, the first side extends along a battery unit of the vehicle. The extruded member defines a ventilation chamber. A battery unit vent is formed through the first side. The battery unit vent is configured to fluidly connect the battery unit and the ventilation chamber when the extruded member is mounted on the vehicle. A package vent is formed through the lower side. The battery pack vent is configured to fluidly connect the ventilation chamber at the lower side to the exterior of the vehicle when the extruded member is mounted on the vehicle.

[0007] Embodiments of the present disclosure may include one or more of the following optional features. In some embodiments, the battery unit vent and the battery pack vent are spaced apart from each other along a longitudinal axis of the extruded member. In some examples, the extruded member includes one or more baffles in the ventilation chamber between the battery unit vent and the battery pack vent. In some aspects, when the extruded member is mounted on the vehicle, a ventilation duct extends from the battery unit through the unit vent and at least partially into the ventilation chamber to fluidly connect the battery unit and the ventilation chamber.

[0008] In some embodiments, the vehicle rocker rail further includes an overflow port formed through the second side. The overflow port is configured to fluidly connect the ventilation chamber at the second side to the exterior of the vehicle when the extruded member is mounted on the vehicle. In further embodiments, the vehicle rocker rail further includes a confluence vent formed through the first side. The confluence vent is configured to fluidly connect a bus area at the battery unit to an overflow chamber of the extruded member when the extruded member is mounted on the vehicle. The overflow port is further configured to fluidly connect the overflow chamber at the second side to the exterior of the vehicle when the extruded member is mounted on the vehicle.

[0009] In some examples, in the case where the extruded member is installed at the vehicle, the extruded member extends along a first side of the battery cell, and the extruded member is connected to a front beam extending along the front side of the battery cell, a rear beam extending along the rear side of the battery cell, an upper panel extending along the upper side of the battery cell, and a lower panel extending along the lower side of the battery cell. In additional examples, the lower panel includes a slide rail that extends along the longitudinal axis of the extruded member in the case where the extruded member is installed at the vehicle. The battery pack vent is configured to fluidly connect the vent chamber to the discharge chamber of the slide rail. In other examples, in the case where the extruded member is installed at the vehicle, a center beam extends along a second side of the battery cell that is opposite the first side of the battery cell. The center beam defines a center vent chamber, and the center beam includes a center battery cell vent and a center battery pack vent. The center battery cell vent is configured to fluidly connect the battery cell and the center vent chamber, and the center battery pack vent is configured to fluidly connect the center vent chamber to the exterior of the vehicle at the lower side of the center beam. In some aspects, in the case where the extruded member is installed on the vehicle, a body member is installed on the second side.

[0010] Another aspect of the present disclosure provides a vehicle battery assembly. The vehicle battery assembly includes a battery cell configured to power a propulsion system of a vehicle in the case where the battery assembly is installed at a vehicle equipped with the vehicle battery assembly. A front beam extends along the front side of the battery cell. A rear beam extends along the rear side of the battery cell that is opposite the front side of the battery cell. An upper panel extends along the upper side of the battery cell. The upper side of the battery cell extends between the front side and the rear side of the battery cell. A lower panel extends along the lower side of the battery cell that is opposite the upper side of the battery cell. A first rocker rail extends along a first side of the battery cell. The first side of the battery cell extends between the front side and the rear side of the battery cell. A second rocker rail extends along a second side of the battery cell that is opposite the first side of the battery cell. The first rocker rail and the second rocker rail each include an extruded member that includes a first side, a second side opposite the first side, and an upper side and a lower side extending between the first side and the second side, respectively. The first side extends along the respective side of the battery cell. The extruded member defines a vent chamber. Each of the first rocker rail and the second rocker rail includes a battery cell vent formed through the first side. The cell vent portion fluidly connects the battery cell and the vent chamber. Each of the first rocker rail and the second rocker rail includes a battery pack vent formed through the lower side. The battery pack vent fluidly connects the vent chamber to the exterior of the vehicle at the lower side of the extruded member. This aspect may include one or more of the following optional features.

[0011] In some aspects, the battery cell vent and the battery pack vent are spaced apart from each other along the longitudinal axis of the extruded member. In some embodiments, the extruded member includes one or more baffles within the vent chamber between the battery cell vent and the battery pack vent. In some examples, a vent duct extends from the battery cell through the cell vent and at least partially into the vent chamber to fluidly connect the battery cell and the vent chamber.

[0012] In some aspects, the first rocker rail and the second rocker rail each respectively include an overflow port formed through a second side of the extruded member. The overflow port fluidly connects the vent chamber to the exterior of the vehicle at the second side of the extruded member. In additional aspects, the first rocker rail and the second rocker rail each respectively include a confluent vent formed through a first side of the extruded member. The confluent vent fluidly connects a bus area at the battery cell to an overflow chamber of the extruded member. The overflow port fluidly connects the overflow chamber to the exterior of the vehicle at the second side of the extruded member. In some embodiments, corresponding body members are mounted at the second side of the extruded member in the case where the vehicle battery assembly is mounted to the vehicle.

[0013] Another aspect of the present disclosure provides a vehicle. The vehicle includes a battery assembly. The battery assembly includes battery cells that power a propulsion system of the vehicle. A front beam extends along a front side of the battery cells. A rear beam extends along a rear side of the battery cells that is opposite the front side of the battery cells. An upper panel extends along an upper side of the battery cells. The upper side of the battery cells extends between the front side and the rear side of the battery. A lower panel extends along a lower side of the battery cells that is opposite the upper side of the battery cells. A first rocker rail extends along a first side of the battery cells. The first side of the battery cells extends between the front side and the rear side of the battery cells. A second rocker rail extends along a second side of the battery cells that is opposite the first side of the battery cells. The first rocker rail and the second rocker rail each respectively include an extruded member that includes a first side, a second side opposite the first side, and upper and lower sides that extend between the first side and the second side, respectively. The first side extends along the respective side of the battery cells. The extruded member defines a vent chamber. Each of the first rocker rail and the second rocker rail includes a battery cell vent formed through the first side. The cell vent portion fluidly connects the battery cell and the vent chamber. Each of the first rocker rail and the second rocker rail includes a battery pack vent formed through the lower side. The battery pack vent fluidly connects the vent chamber at the lower side to the exterior of the vehicle. This aspect may include one or more of the following optional features.

[0014] In some aspects, the extrusion member includes one or more baffles within a ventilation chamber between the cell vents and the pack vents. In some embodiments, the bottom panel includes corresponding slide rails extending along the respective longitudinal axes of the extrusion member. The corresponding pack vents fluidly connect the discharge chamber to the respective ventilation chambers of the slide rails.

[0015] Details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings described herein are for illustrative purposes only for the selected configurations and are not intended to limit the scope of the present disclosure.

[0017] Figure 1 is a top perspective view of a battery assembly for powering a vehicle's propulsion system.

[0018] Figure 2 is a sectional view taken along Figure 1 line 2-2 of

[0019] Figure 2A is Figure 2 an enlarged view of region 2A of

[0020] Figure 2B is Figure 2 an enlarged view of region 2B of

[0021] Figure 3A is a sectional view taken along Figure 1 line 3-3 of

[0022] Figure 3B is a sectional view taken along Figure 1 line 3-3 of

[0023] Figure 4 is a bottom perspective view of the battery assembly.

[0024] Figure 5 is a sectional view taken along Figure 1 line 5-5 of

[0025] Figure 6 is another top perspective view of the battery assembly.

[0026] Figure 7A is Figure 6 a perspective sectional view of region 7 of

[0027] Figure 7B is Figure 6 another sectional view of region 7 of

[0028] Figure 8 is another upper perspective view of the battery assembly.

[0029] Figure 9A is Figure 8 an enlarged view of the battery assembly at region 9 of

[0030] Figure 9B is Figure 8 an enlarged view of the rear beam at region 9 of

[0031] Figure 10 is a rear perspective view of the battery assembly.

[0032] Figure 11 is a perspective view of the ventilation air duct of the battery cells of the battery assembly.

[0033] Figure 12 is a cross-sectional view of the battery assembly, in which a body member is mounted to the outside of the side beams of the battery assembly.

[0034] In all the figures, corresponding reference numerals denote corresponding parts. DETAILED DESCRIPTION

[0035] Example configurations will now be described more fully with reference to the accompanying drawings. The example configurations are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those of ordinary skill in the art that the example configurations may be embodied in many different forms and that specific details and example configurations should not be construed as limiting the scope of this disclosure.

[0036] The terms used herein are for the purpose of describing particular example configurations only and are not intended to be limiting. As used herein, the singular articles "a" and "the" may also be intended to include the plural forms, unless the context clearly indicates otherwise. The terms "comprising," "including," and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as necessarily requiring them to be performed in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

[0037] When an element or layer is referred to as being “on another element or layer,” “bonded to,” “connected to,” “attached to,” or “coupled to” another element or layer, it can be directly on the other element or layer, directly bonded, connected, attached, or coupled to the other element or layer, or there can be intervening elements or layers. In contrast, when an element is referred to as being “directly on another element or layer,” “directly bonded to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there can be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a like manner (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0038] The terms “first,” “second,” “third,” etc. may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply an order or sequence. Thus, a first element, component, region, layer, or section discussed below may be termed a second element, component, region, layer, or section without departing from the teachings of the exemplary configuration.

[0039] In this application, including the definitions below, the term “module” may be replaced with the term “circuit.” The term “module” may refer to an application specific integrated circuit (ASIC), be part of, or include, the same; a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinatorial logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; a memory (shared, dedicated, or group) that stores code executed by the processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system on a chip.

[0040] As used above, the term "code" can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. The term "shared processor" includes a single processor that executes some or all of the code from multiple modules. The term "group processor" includes a processor that, in combination with additional processors, executes some or all of the code from one or more modules. The term "shared memory" encompasses a single memory that stores some or all of the code from multiple modules. The term "group memory" includes a memory that, in combination with additional memories, stores some or all of the code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium". The term "computer-readable medium" does not include transient electrical and electromagnetic signals propagated through a medium and can thus be considered tangible and non-transient memory. Non-limiting examples of non-transitory memory include tangible computer-readable media, which include non-volatile memory, magnetic memory, and optical memory.

[0041] The apparatus and methods described in this application can be implemented in part or in whole by one or more computer programs executed by one or more processors. The computer programs include processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. The computer programs can also include and / or rely on stored data.

[0042] A software application (i.e., a software resource) can refer to computer software that causes a computing device to perform tasks. Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0043] Non-transitory memory can be a physical device for temporarily or permanently storing programs (e.g., sequences of instructions) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used for firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM), and magnetic disks or tapes.

[0044] These computer programs (also called programs, software, software applications or code) include machine instructions for a programmable processor and can be implemented in high-level procedural and / or object-oriented programming languages and / or assembly / machine languages. As used herein, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., a magnetic disk, optical disk, memory, programmable logic device (PLD)) that provides machine instructions and / or data to a programmable processor, including a machine-readable medium that receives the machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal that provides machine instructions and / or data to a programmable processor.

[0045] The various implementations of the systems and techniques described herein can be implemented in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can include implementations in one or more computer programs executable and / or interpretable on a programmable system including at least one programmable processor which may be special purpose or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

[0046] The processes and logical flows described in this specification can be performed by one or more programmable processors (also referred to as data processing hardware) that execute one or more computer programs to perform functions by operating on input data and generating output. The processes and logical flows can also be performed by special purpose logic circuitry, such as an FPGA (field programmable gate array) or ASIC (application specific integrated circuit). As an example, processors suitable for the execution of a computer program include both general and special purpose microprocessors, and any one or more processors of any type of digital computer. Generally, a processor will receive instructions and data from a read only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include one or more mass storage devices for storing data (such as magnetic disks, magneto-optical disks, or optical disks), or be operatively coupled to receive data from or transfer data to or both. However, a computer need not have such devices. Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

[0047] For providing interaction with a user, one or more aspects of the present disclosure may be implemented on a computer having a display device (such as a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen) for displaying information to the user and optionally a keyboard and a pointing device (such as a mouse or a trackball) by which the user can provide input to the computer. Other kinds of devices may also be used to provide interaction with the user; for example, feedback provided to the user may be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including acoustic, speech, or tactile input. Additionally, a computer may interact with a user by sending documents to and receiving documents from the device used by the user; for example, by sending a web page to a web browser on a client device of the user in response to a request received from the web browser.

[0048] Referring now to the drawings and the illustrated configurations depicted therein, a structural battery assembly or battery pack 100 for powering a propulsion system of a battery-powered vehicle 10, such as an electric vehicle (EV) or a plug-in hybrid electric vehicle (PHEV), includes a plurality of battery cells 102, 102a-b housed between an upper panel 104 and a lower panel 106 Figure 1 andFigure 2 )。In the illustrated example, the battery assembly 100 includes a first battery cell (or first row of battery cells) 102a and a second battery cell (or second row of battery cells) 102b, and it should be understood that the battery assembly 100 can include any suitable number of battery cells 102 for powering the propulsion system of the vehicle 10. The front beam 108 extends along the front side of the battery cells 102 and seals the front end of the battery assembly 100, and the rear beam 110 extends along the opposite rear side of the battery cells 102 and seals the rear end of the battery assembly 100. As discussed further below, the battery cells 102, the front beam 108, and the rear beam 110 are disposed between a first side beam or rocker rail 200, 200a and a second side beam or rocker rail 200, 200b, wherein the respective rocker rails 200 provide longitudinal support members for the battery assembly 100 and can provide a body rocker rail along the respective sides of the vehicle 10.

[0049] In the case where the battery assembly 100 is installed at the vehicle 10, the upper panel 104 is coupled to the rocker rails 200 and extends between the rocker rails 200 along the upper side of the battery cells 102 to form the floor panel of the body. That is, components for the passenger compartment, such as the rails 12 for mounting the seats of the vehicle 10 and the vehicle wiring harness 14, can be disposed and / or mounted to the structural members of the battery assembly 100 along the upper side or outer side of the upper panel 104. Similarly, the lower panel 106 is coupled to the rocker rails 200 and extends between the rocker rails 200 and along the lower side of the battery cells 102 to provide the lower outer surface of the vehicle 10. For example, the lower panel 106 can include one or more skid rails 112 extending from the lower side or outer side of the lower panel 106 for reducing damage to the battery assembly 100 and the vehicle 10 during vehicle travel in a low ground clearance situation. One or more thermal elements 114 (such as cold plates, thermal adhesives, etc.) can be disposed between the battery cells 102 and the lower panel 106 and / or the upper panel 104 for improving heat transfer from the battery cells 102, thereby improving the cooling of the battery assembly 100.

[0050] The front beam 108 and the rear beam 110 provide a cell-stack compression plate and are clamped between the first rocker rail 200a and the second rocker rail 200b. Thus, in the case where the first rocker rail 200a and the second rocker rail 200b serve as the side sills of the vehicle 10, the rocker rails 200 seal the side walls of the battery assembly 100 and provide a progressive cross-vehicle structure. The front beam 108 and the rear beam 110 seal the front and rear walls of the battery assembly 100 and provide cross-vehicle load transfer. A portion of the rocker rail 200 may extend beyond the front beam 108 to provide an installation space 16, for example, for contactors, wiring, and other components associated with the battery assembly 100. Optionally, the longitudinal center beam 300 extends parallel to the longitudinal axis A of the rocker rail 200 200 and extends between the front beam 108 and the rear beam 110 and separates the first battery cell 102a and the second battery cell 102b. The center beam 300 is not present in an example of the battery assembly 100 having only a single battery cell 102 (or a single row of battery cells). Thus, the structural battery system 100 can include as few as six or seven structural components to form the frame or enclosure of the battery assembly 100. Although described herein as a cell-to-body (CTB) system, the structural battery assembly 100 can be implemented as part of a cell-to-pack (CTP) or CTB electric vehicle (EV) propulsion system.

[0051] Reference Figure 2 and Figure 2A , the first rocker rail 200a extends along the first side of the battery cell 102 and along the first side of the vehicle 10, and the second rocker rail 200b extends along the second side of the battery cell 102 and along the second side of the vehicle 10. Although only one rocker rail 200 will be further described herein, it should be understood that the rocker rail 200 can have a similar structure and features along both sides of the battery assembly 100.

[0052] As Figure 2AAs shown, the rocker arm track 200 includes an extruded member, such as an extruded aluminum member, having a first side 202, a second side 204 opposite the first side 202, and an upper side 206 and a lower side 208 extending between the first side 202 and the second side 204, respectively. One or more internal structural members 210 extend between the first side 202, the second side 204, the upper side 206, and the lower side 208. The first side 202 extends along and abuts the battery cell 102, and the second side 204 extends along the outer side of the vehicle 10. As discussed further below, the rocker arm track 200 defines an internal ventilation chamber 212 bounded by one or more of the first side 202, the second side 204, the upper side 206, the lower side 208, and one or more of the internal structural members 210.

[0053] One or more first vents or battery cell vents 214 are formed through the first side 202 and fluidly connect the ventilation chamber 212 and the battery cell 102. For example, the rocker arm track 200 may include one or more battery cell vents 214 that abut each respective battery cell 102. Each battery cell vent 214 includes a first battery cell opening or port 216 formed through the first side 202 of the rocker arm track 200 and a ventilation air duct 116 that extends from the battery cell 102 through the battery port 216 and along the battery cell vent 214 and at least partially into the ventilation chamber 212 to fluidly connect the ventilation chamber 212 and the battery cell 102. The ventilation air duct 116 and / or the battery cell 102 at and near the ventilation air duct 116 may be sealed to the first side 204 of the rocker arm track 200, such as via a sealing element or gasket or adhesive member 118 that surrounds the ventilation air duct 116 between the first side 202 and the battery cell 102. A blast seal or cap 120 (such as a mica cap) may extend over one or more openings of the ventilation air duct 116 for sealing the battery cell 102 during normal use. During thermal runaway, a failure of the battery cell 102 may cause the blast seal 120 to burst, allowing hot gases, flames, and / or particulates (collectively referred to as emissions) to flow from the battery cell 102 through the ventilation air duct 116 and the battery cell vent 214 into the ventilation chamber 212.

[0054] One or more second vents or battery pack vents 218 are formed through the lower side 208 and fluidly connect the plenum chamber 212 and the surrounding environment external to the vehicle 10 at the lower side 208 of the rocker rail 200. For example, the rocker rail 200 may include one or more battery pack vents 218 corresponding to each respective battery cell 102a. Each battery pack vent 218 includes a second battery pack opening or port 220 formed through the lower side 208 of the rocker rail 200 and a vent plug or nozzle 222 that extends at least partially within the plenum chamber 212 along the battery pack vent 218 and extends outwardly from the lower side 208 to fluidly connect the plenum chamber 212 to the exterior of the vehicle 10.

[0055] The extruded rocker rail 200 includes one or more baffles or plates or screens 224 within the plenum chamber 212 between the battery cell vents 214 and the battery pack vents 218 to dissipate or eliminate emissions discharged from the battery cells 102. For example, and as Figure 2A shown, a passage 226 is formed through the baffle 224 and the baffle 224 extends between the lower side 208 and the internal structure 210 to separate or isolate or define a tumble region 228 of the fluid connection of the plenum chamber 212. That is, the baffle 224 and other structures of the rocker rail 200 provide a tumble-inducing geometry to enhance the cooling of emissions and promote the collection of particles within the tumble region 228 as the emissions flow through the plenum chamber 212 and out of the battery pack vents 218. Additionally, the battery cell vents 214 and the battery pack vents 218 are axially offset from each other along the longitudinal axis A of the rocker rail 200 200 to provide additional dissipation or blockage of emissions within the plenum chamber 212.

[0056] Some portions of the extruded rocker rail 200 (such as the internal structure 210 and portions of the upper side 206 at or near the battery cell vents 214) may have a greater thickness to reduce or eliminate the risk of melting of the rocker rail 200 at these portions during a fault event. For example, the portion of the upper side 206 between the plenum chamber 212 and the high voltage (HV) bus or electrical connection 122 of the battery cell 102 is thicker or reinforced to isolate the emissions from the HV bus 122, which reduces or eliminates the risk of HV arc discharge and thermal runaway spreading to additional battery cells 102.

[0057] Accordingly, the rocker rail 200 includes a ventilation chamber 212 to provide an emissions passage between the battery cell 102 and the surrounding environment external to the vehicle 10. The passage between the battery cell vent 214 and the battery pack vent 218 includes a series of ventilation walls to form baffles or dissipators to diffuse jet energy and falling particles. These baffle passages are integrated with the structural side beam 200 to isolate the gas from the HV bus 122 and reduce the risk of HV arcing. Additionally, each side beam 200 includes a crushing structure or crushing region 230 at the second side 204 such that the side beam 200 can provide rocker rail functionality. In other words, the rocker rail 200 provides side crush progressive wall stiffness to form an effective inner tub portion.

[0058] Reference Figure 2B 、 Figure 3A and Figure 3B , the longitudinal center beam 300 can provide a ventilation function similar to that of the side beam 200 to the opposite side or the central region of the battery cell 102. In an example having two or more rows of battery cells 102, the center beam 300 extends between the front beam 108 and the rear beam 110 along the second side of the battery cells 102 opposite the rocker rail 200, and the longitudinal axis A of the center beam 300 300 is parallel to the longitudinal axis A of the rocker rail 200 200 . The center beam 300 includes an extruded member, such as an extruded aluminum member, having a first side 302, a second side 304 opposite the first side 302, and an upper side 306 and a lower side 308 extending between the first side 302 and the second side 304, respectively. One or more internal structures 310 may extend between the first side 302, the second side 304, the upper side 306, and the lower side 308. The first side 302 extends along and abuts the first battery cell 102a, and the second side 304 extends along and abuts the second battery cell 102b. As discussed further below, the center beam 300 defines a central ventilation chamber 312 defined by one or more of the first side 302, the second side 304, the upper side 306, the lower side 308, and one or more of the internal structure members 310.

[0059] One or more battery cell vents 314 are formed through the first side 302 for fluidly connecting the central vent chamber 312 and the first battery cell 102a, and one or more cell vents 314 are formed through the second side 304 for fluidly connecting the central vent chamber 312 and the second battery cell 102b. Each battery cell vent 214 includes a battery opening or port 316 formed through the respective side of the central beam 300 and a vent duct 116 that extends from the battery cell 102 through the battery port 316 and along the battery cell vent 314 and at least partially into the central vent chamber 312 to fluidly connect the vent chamber 312 and the battery cell 102.

[0060] One or more battery pack vents 318 are formed through the lower side 308 and fluidly connect the central vent chamber 312 and the surrounding environment external to the vehicle 10 at the lower side 308 of the central beam 300. Each battery pack vent 318 includes a battery pack opening or port 320 formed through the lower side 308 of the central beam 300 and a vent plug 322 that extends along the battery pack vent 318 and at least partially within the vent chamber 312 and extends outwardly from the lower side 308 to fluidly connect the vent chamber 312 to the exterior of the vehicle 10.

[0061] The extruded central beam 300 includes one or more baffles 324 within the central vent chamber 312, the one or more baffles 324 being between each battery cell vent 314 and the battery pack vent 318 to dissipate or diffuse emissions discharged from the battery cell 102. The baffle 324 includes a passage 326 formed therethrough, and the baffle 324 divides or isolates or defines a tumbling region 328 of fluid connection of the central vent chamber 312. Further, the battery cell vents 314 and the battery pack vents 318 (and the passage 326 through the baffle 324) are axially offset from each other along the longitudinal axis A of the central beam 300 300 to provide additional dissipation or blocking of emissions within the central vent chamber 312 ( Figure 3A and Figure 3B ). Portions of the extruded central beam 300 have a greater thickness to reduce or eliminate the risk of melting of the central beam 300 during thermal runaway. For example, a portion of the internal structure 310 between the central vent chamber 312 of the battery cell 102 and the HV bus 122 is thicker or reinforced to isolate the emissions from the HV bus 122.

[0062] Accordingly, the center beam 300, together with the rocker rail 200, provides an emissions path between the battery cell 102 and the surrounding environment, which reduces or eliminates the impact of thermal runaway at one battery cell 102 on additional battery cells 102 within the battery assembly 100. Additionally, the center beam 300 and the rocker rail 200 structurally support the battery cells 102 for mounting in the vehicle 10. For example, the rocker rail 200 includes a protrusion or lip 232 extending from the first side 202 for supporting the lower surface of the battery cell 102, and the center beam 300 further includes protrusions or lips 332 extending from the first side 302 and the second side 304 for supporting the lower surfaces of two battery cells 102.

[0063] As Figure 2 - 4 shown, the battery pack vents 218 of the rocker rail 200 and the battery pack vents 318 of the center beam 300 are fluidly connected to corresponding emissions chambers 124 formed along the slide rails 112 of the lower panel 106. That is, the corresponding slide rails 112 of the lower panel 106 extending along the longitudinal axis A 200 of the rocker rail 200 and extending along the longitudinal axis A 300 of the center beam 300 define the emissions chambers 124, which are fluidly connected to the corresponding ventilation chambers 212 and the center ventilation chamber 312 via the battery pack vents 218 of the rocker rail 200 and the battery pack vents 318 of the center beam 300. Corresponding ports or openings 126 are formed through the slide rails 112 for fluidly connecting the emissions chambers 124 to the surrounding environment, and the openings 126 are axially offset relative to the corresponding battery pack vents 218, 318. The ends 128 of the slide rails 112 may be sealed or closed to ensure that emissions are directed from the battery pack vents 218, 318 and outwardly from the openings 126 to direct the emissions downward. Thus, when emissions are directed from the battery pack vents 218, 318, the emissions are further dissipated within the emissions chambers 124 of the slide rails 112 to reduce the heat of the emissions and prevent particles from reaching the surrounding environment, thereby reducing or eliminating the risk of heat and particles affecting the grass, oil, and / or road below the vehicle 10.

[0064] Furthermore, the slide rails 112 can provide protection for the battery assembly 100 and the lower surface of the vehicle 10 in the case of low ground clearance. The ends 128 of the slide rails 112 can be inclined or angled or curved or wavy to reduce the risk of the slide rails 112 getting caught on obstacles under the vehicle 10, which could otherwise cause damage or removal of the slide rails 112.

[0065] Reference Figure 5, a flood port 234 is formed through a second side 204 of the rocker rail 200 and fluidly connects the plenum chamber 212 to the exterior of the vehicle 10 at the second side 204. For example, the flood port 234 may be accessible from the exterior of the vehicle 10, such as at the wheel well region of the vehicle 10. The flood port 234 includes an opening or through-hole 236 formed through the second side 204 of the rocker rail 200 and a flood plug or nozzle 238 that extends along the flood port 234 and is at least partially within the plenum chamber 212 to fluidly connect the plenum chamber 212 to the exterior of the vehicle 10 at the second side 204. The flood port 234 is configured to interface with a water source, such as a coupling end of a hose, for delivering water through the plenum chamber 212 to the battery cells 102 during a fault event. For example, an emergency responder, such as a firefighter, may insert or attach a coupling end of a hose at the flood port 234 to extinguish and / or cool the battery cells 102 experiencing thermal runaway. Since the plenum chamber 212 extends along the rocker rail 200, water can be delivered from the flood port 234 along the plenum chamber 212 (and through the respective channels 226 of the baffle 224) and through one or more cell vents 214 to extinguish and / or cool one or more battery cells 102.

[0066] In some examples, one or more third vents or bus vents 240 are formed through the first side 202 and fluidly connect the overflow chamber 242 and / or the plenum chamber 212 of the extruded rocker rail 200 to the bus region 122 of the battery cells 102. The flood port 234 fluidly connects the overflow chamber 242 to the exterior of the vehicle 10 such that water can be delivered to one or more bus vents 240 and one or more cell vents 214 simultaneously. Delivering water to the bus region 122 of the battery cells 102 provides enhanced cooling and further reduces the spread of thermal runaway between the battery cells 102.

[0067] Now refer to Figure 1 and Figures 6 to 10, since the side beam 200 provides the rocker rail function of the vehicle 10, the structural integrity of the battery assembly 100 contributes to the structural integrity and safety of the vehicle 10. Accordingly, an upper panel 104 extending above and along the battery cells 102 and the center beam 300 and a lower panel 106 extending below and along the battery cells 102 and the center beam 200 are coupled to the front end beam 108, the rear end beam 110, and the side beam 200 to seal the battery assembly 100. For example, a plurality of mechanical fasteners 602 (such as bolts or other suitable threaded fasteners) are disposed around the respective peripheral regions of the upper panel 104 and the lower panel 106 (and optionally along the center beam 300) to couple the upper panel 104 and the lower panel 106 to the frame structure. The mechanical fasteners 602 that couple the lower panel 106 to the frame structure can be disposed as close as possible to the battery cells 102 to improve the seal between the battery cell compartment and the environment. For example, the mechanical fasteners 602 can at least partially extend within the ventilation chamber 212 through the lower panel 106 and the lower side 208 of the rocker rail 200 to form a tight seal between the lower panel 106 and the rocker rail 200 at or as close as possible to the first side 204. This further encourages the exhaust gas to flow through the battery cell vents 214 into the ventilation chamber 212.

[0068] In addition, since at least a portion of the first side 204 of the rocker rail 200 can be spaced apart from the battery cells 102 to accommodate the bus bar region 122, a reinforcement 604, such as a rib or an additional metal plate, such as a tailor-welded blank, can be provided or formed along the upper panel 104 at a region corresponding to the bus bar region 122. In other words, the reinforcing rib 604 extends along or within the upper panel 104 at a region corresponding to the bus bar region 122 and extends between the rocker rail 200 and the battery cells 102. This helps to prevent the upper panel 104 from peeling off the rocker rail 200 and the battery cells 102 in the event of a vehicle impact. The reinforcing rib 604 may not be included in a portion of the upper panel 104 corresponding to the mounted component (such as the seat track 12) such that the seat track 12 can be rigidly bolted to the side beam 200 and / or the center beam 300 through the upper panel 104.

[0069] To clamp the front end beam 108 and the rear end beam 110 between the rocker rails 200, one or more slots 244 are formed through the rocker rails 200 at corresponding mating positions of these end beams. The front end beam 108 and the rear end beam 110 may each include a cast structure, such as a cast aluminum structure, having threaded holes formed at the respective ends for receiving threaded fasteners 602 that extend through the slots 244. The slots 244 have component tolerances. That is, due to the assembly sequence and the adhesive thickness, after the battery cell 102 is disposed between the end beams 200 and / or the center beam 300, the end beams 108, 110 are mated to the side beams 200, allowing the slots 244 to accommodate changes in the front-to-back stack length. The width change and thus the distance between the battery cell 102 and the first side 202 of the side beam can be accommodated by the battery air duct 116.

[0070] In the case where the front end beam 108 and the rear end beam 110 are joined to the rocker rails 200, the respective ends 346 of the center beam 300 are captured within respective cavities or recesses 146 formed at the inner sides of the front end beam 108 and the rear end beam 110. That is, each of the front end beam 108 and the rear end beam 110 includes a respective recess 146, and the shape or profile of the recess 146 corresponds to the shape or profile of the end 346 of the center beam 300. For example, the center beam end 346 and the end beam cavity 146 may be formed as a geometric imprint or a ball-and-socket joint with a minimum clearance (e.g., 1 millimeter or less). This ensures that during a frontal or rear vehicle impact, even if the vehicle 10 is impacted at an angle or offset with respect to the center beam 300, the load can be transferred through the center beam 300, thereby reducing the transfer of impact loads to the battery cell 102. Additionally, the rear end beam 110 may have a ribbed or pocketed structure at the outer surface to provide an impact absorbing or crush zone 148.

[0071] In some examples, and as Figure 12 shown, the vehicle body member or rocker buffer 1200 may be mounted to the rocker rails 200 at the exterior of the vehicle 10. The rocker buffer 1200 is mounted to the second side 204 of the rocker rails 200, such as at the crush zone 230, via threaded fasteners 602 or any suitable fastening means (e.g., clips, adhesives, etc.). Since the rocker rails 200 provide the structural components of the battery assembly 100, damage to the rocker rails 200 may result in extensive repairs. Thus, the rocker buffer 1200 is configured to absorb or attenuate low-intensity impacts at the sides of the vehicle 10 and reduce or eliminate the load transferred to the rocker rails 200. This allows for the repair and / or replacement of the rocker buffer 1200 after a vehicle impact and avoids the risk of damaging the rocker rails 200.

[0072] Numerous embodiments have been described. However, it should be understood that various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the appended claims.

[0073] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. The individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable and may be used in a selected configuration, even if not specifically shown or described. It may also vary in many ways. Such variations should not be regarded as a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A vehicle rocker arm track, the vehicle rocker arm track comprising: An extruded member configured to be mounted on a vehicle equipped with the vehicle rocker arm track, the extruded member including a first side, a second side opposite the first side, and upper and lower sides extending between the first side and the second side, respectively, the extruded member being mounted on the vehicle, the first side extending along a battery unit of the vehicle, and the extruded member defining a ventilation chamber; A battery unit vent formed through the first side, the battery unit vent being configured to fluidly connect the battery unit and the ventilation chamber when the extruded member is mounted on the vehicle; And A battery pack vent formed through the lower side, the battery pack vent being configured to fluidly connect the ventilation chamber at the lower side to the exterior of the vehicle when the extruded member is mounted on the vehicle.

2. The vehicle rocker arm track according to claim 1, wherein the battery unit vent and the battery pack vent are spaced apart from each other along a longitudinal axis of the extruded member.

3. The vehicle rocker arm track according to claim 1, wherein the extruded member includes one or more baffles in the ventilation chamber between the battery unit vent and the battery pack vent.

4. The vehicle rocker arm track according to claim 1, wherein, When the extruded member is mounted on the vehicle, a ventilation duct extends from the battery unit through the battery unit vent and at least partially into the ventilation chamber to fluidly connect the battery unit and the ventilation chamber.

5. The vehicle rocker arm track according to claim 1, further comprising an overflow port formed through the second side, the overflow port being configured to fluidly connect the ventilation chamber at the second side to the exterior of the vehicle together with the extruded member mounted on the vehicle.

6. The vehicle rocker arm track according to claim 5, further comprising a confluence ventilation port formed through the first side, the confluence ventilation port being configured to fluidly connect a bus area at the battery unit to an overflow chamber of the extruded member when the extruded member is mounted on the vehicle, and the overflow port being further configured to fluidly connect the overflow chamber at the second side to the exterior of the vehicle when the extruded member is mounted on the vehicle.

7. The vehicle rocker rail according to claim 1, wherein, When the extruded member is mounted on the vehicle, the extruded member extends along a first side of the battery unit, and the extruded member is connected to a front beam extending along a front side of the battery unit, a rear beam extending along a rear side of the battery unit, an upper panel extending along an upper side of the battery unit, and a lower panel extending along a lower side of the battery unit.

8. The vehicle rocker rail according to claim 7, wherein, The lower panel includes a slide rail that extends along a longitudinal axis of the extruded member when the extruded member is mounted on the vehicle, and the battery pack vent is configured to fluidly connect the ventilation chamber to an emission chamber of the slide rail.

9. The vehicle rocker rail according to claim 7, wherein, With the extrusion molding member mounted at the vehicle, a center beam extends along a second side of the battery unit that is opposite to the first side of the battery unit. The center beam defines a center ventilation chamber and includes a center battery unit vent and a center battery pack vent. The center battery unit vent is configured to fluidly connect the battery unit and the center ventilation chamber. The center battery pack vent is configured to fluidly connect the center ventilation chamber to the exterior of the vehicle at a lower side of the center beam.

10. The vehicle rocking rail according to claim 1, wherein, With the extrusion molding member mounted at the vehicle, a body member is mounted at the second side.

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