Rechargeable energy storage system including heat exchange component with cooling system

Abstract

A battery assembly includes a housing having a cell support surface and a plurality of sidewalls that collectively define an interior region. A plurality of battery cells are arranged in the interior region. A heat exchange member is mounted to the housing, the heat exchange member including a bottom plate. A cooling system is disposed in the heat exchange member. The cooling system includes an inflatable bladder disposed between the battery cell support surface and the base plate. The inflatable bladder is selectively inflated with a cooling fluid to come into contact with the battery cell support surface.

Description

Technical Field

[0001] The present disclosure relates to the field of electric vehicles and, more particularly, to an electric vehicle having a rechargeable energy storage system (RESS) that includes a heat exchange member plate having a cooling system that includes an expandable bladder. Background Art

[0002] Many newer vehicles are being manufactured with electric propulsion systems. Electric propulsion systems, whether all-electric or hybrid-electric systems, rely on an electric motor that is powered by energy stored in a rechargeable energy storage system (RESS) or a battery assembly having a plurality of battery cells. In operation, the battery cells generate heat. The heat reduces battery efficiency. To remove the heat generated by the battery cells, many vehicles include a cooling system that circulates a cooling fluid or coolant in thermal contact with the battery cells.

[0003] In some cases, the cooling system includes a plate disposed within a battery housing. The battery cells rest on the plate. The coolant passes through conduits in the plate in a heat-exchanging relationship with the battery cells. The coolant absorbs heat from the battery cells and then passes through a heat exchanger before cycling back into the plate. Heat exchange is limited by the surface area of the conduits in contact with the battery cells or the battery cell support surface. Increasing the surface contact area would improve cooling. Accordingly, it is desirable to provide a system that increases the surface area of the contact heat exchange surface to improve cooling and battery operation. Summary of the Invention

[0004] According to a non-limiting example, a battery assembly includes a housing having a battery cell support surface and a plurality of sidewalls that together define an interior region. A plurality of battery cells are disposed within the interior region. A heat exchange member is mounted to the housing, the heat exchange member including a bottom plate. A cooling system is disposed within the heat exchange member. The cooling system includes an expandable bladder disposed between the battery cell support surface and the bottom plate. The expandable bladder is selectively inflated with a cooling fluid to bring it into contact with the battery cell support surface.

[0005] In addition to one or more of the features described herein, a plurality of channels extend between the battery cell support surface and the bottom plate, wherein the expandable bladder includes a plurality of expandable bladders, each of the plurality of expandable bladders being disposed within a corresponding one of the plurality of channels.

[0006] In addition to one or more of the features described herein, a cooling fluid supply system includes an inlet manifold having an inlet conduit and an outlet manifold having an outlet conduit, the inlet conduit being fluidly connected to each of the plurality of expandable bladders and the outlet conduit being fluidly connected to each of the plurality of expandable bladders.

[0007] In addition to one or more features described herein, the heat exchange member includes a first edge, a second edge opposite the first edge, a first side edge, and a second side edge opposite the first side edge. A first reinforcing member extends along the first edge, and a second reinforcing member extends along the second edge. The first reinforcing member and the second reinforcing member are coupled to the battery cell support surface and the bottom plate.

[0008] In addition to one or more features described herein, a plurality of reinforcing elements extend between and are connected to the first reinforcing member and the second reinforcing member, and each of the plurality of channels is defined by adjacent ones of the plurality of reinforcing elements.

[0009] In addition to one or more features described herein, selected ones of the plurality of reinforcing elements include a first recess for receiving the inlet conduit and a second recess for receiving the outlet conduit.

[0010] In addition to one or more features described herein, each of the plurality of reinforcing elements includes an exhaust passage, and the battery cell support surface includes a plurality of exhaust passages fluidly connecting the internal region and the exhaust passage.

[0011] In addition to one or more features described herein, the battery cell support surface fluidly isolates the internal region from a plurality of inflatable bladder-like streams.

[0012] In addition to one or more features described herein, the bottom plate includes a non-planar surface having a plurality of protrusions, and each of the plurality of protrusions extends toward a corresponding one of the plurality of channels.

[0013] In addition to one or more features described herein, one of a thermal interface material (TIM) layer and an adhesive layer is disposed between the plurality of battery cells and the battery cell support surface.

[0014] By way of non-limiting example, a vehicle includes a body, a plurality of wheels supporting the body, an electric drive unit supported in the body, and a battery assembly operably connected to the electric drive unit. The battery assembly includes a housing that includes a battery cell support surface and a plurality of side walls that together define an internal region. A plurality of battery cells are disposed in the internal region. A heat exchange member is mounted to the housing. The heat exchange member includes a bottom plate. A cooling system is disposed in the heat exchange member. The cooling system includes an inflatable bladder disposed between the battery cell support surface and the bottom plate. The inflatable bladder is selectively inflated with a cooling fluid to bring it into contact with the battery cell support surface.

[0015] In addition to one or more features described herein, a plurality of channels extend between the cell support surface and the bottom plate, wherein the expandable bladder includes a plurality of expandable bladders, and each of the plurality of expandable bladders is disposed in a corresponding one of the plurality of channels.

[0016] In addition to one or more features described herein, the coolant supply system includes an inlet manifold having an inlet conduit and an outlet manifold having an outlet conduit, the inlet conduit being fluidly connected to each of the plurality of expandable bladders, and the outlet conduit being fluidly connected to each of the plurality of expandable bladders.

[0017] In addition to one or more features described herein, the heat exchange member includes a first edge, a second edge opposite the first edge, a first side edge, and a second side edge opposite the first side edge, a first reinforcing member extending along the first edge, and a second reinforcing member extending along the second edge, the first reinforcing member and the second reinforcing member being coupled to the cell support surface and the bottom plate.

[0018] In addition to one or more features described herein, a plurality of reinforcing elements extend between the first reinforcing member and the second reinforcing member and are connected to the first reinforcing member and the second reinforcing member, and each of the plurality of channels is defined by adjacent reinforcing elements of the plurality of reinforcing elements.

[0019] In addition to one or more features described herein, selected ones of the plurality of reinforcing elements include a first recess for receiving the inlet conduit and a second recess for receiving the outlet conduit.

[0020] In addition to one or more features described herein, each of the plurality of reinforcing elements includes an exhaust passage, and the cell support surface includes a plurality of exhaust passages fluidly connecting the internal region and the exhaust passage.

[0021] In addition to one or more features described herein, the cell support surface fluidly isolates the internal region from the plurality of expandable bladders.

[0022] In addition to one or more features described herein, the bottom plate includes a non-planar surface having a plurality of protrusions, and each of the plurality of protrusions extends toward a corresponding one of the plurality of channels.

[0023] In addition to one or more features described herein, one of a thermal interface material (TIM) layer and an adhesive layer is disposed between the plurality of cells and the cell support surface.

[0024] The above features and advantages of the present disclosure, as well as other features and advantages, are apparent from the following detailed description when taken in conjunction with the accompanying drawings. Brief Description of the Drawings

[0025] Other features, advantages, and details appear only by way of example in the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a left side view of a vehicle including a rechargeable energy storage system (RESS) according to a non - limiting example, the rechargeable energy storage system having a heat exchange member including a battery cell support surface and an expandable cooling system;

[0027] Figure 2 is according to a non - limiting example Figure 1 partial perspective view of the RESS;

[0028] Figure 3 is according to a non - limiting example along Figure 2 cross - sectional view of the RESS taken along line 3 - 3 in

[0029] Figure 4 is according to a non - limiting example along Figure 2 cross - sectional view of the RESS taken along line 4 - 4 in

[0030] Figure 5 is according to a non - limiting example Figure 2 top view of the RESS with the battery cell support surface removed;

[0031] Figure 6 is according to another non - limiting example Figure 2 cross - sectional view of the RESS;

[0032] Figure 7 is a top view of the RESS with the battery cell support surface removed according to yet another non - limiting example; and

[0033] Figure 8 is according to a non - limiting example a partial side cross - sectional view of the RESS taken along line 8 - 8 through Figure 7 Detailed Description

[0034] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals represent the same or corresponding components and features.

[0035] According to a non - limiting example, the vehicle is at Figure 1 ​Generally, it is represented by 10 in the whole. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20, and the passenger compartment 20 has a seat 23 positioned behind a dashboard 26. A steering controller 30 is arranged between the seat 23 and the dashboard 26. The steering control 30 is operated to control the orientation of a selected wheel among the plurality of wheels 16. The vehicle 10 includes an electric drive unit 34 that supplies power to one or more of the plurality of wheels 16.

[0036] A rechargeable energy storage system (RESS) or battery assembly 38 is arranged in the body 12 and supplies power to the electric drive unit 34. At this time, it should be understood that the positions of the electric drive unit 34 and the battery assembly 38 can be changed. As Figure 2 shown, the battery assembly 38 includes a housing 50, and the housing 50 has a bottom wall 52 that defines a battery cell support surface 53 and a plurality of side walls 54 that jointly define an internal area 58.

[0037] In a non-limiting example, the plurality of side walls 54 include a first side wall 60, a second side wall 61, a third side wall 62, and a fourth side wall 63. The housing 50 also includes a cover 66 ( Figure 3 ). A plurality of battery cells 68 are arranged in the internal area 58 of the housing 50. The battery cells 68 rest on the battery cell support surface 52. An interface layer 70 ( Figure 3 ) can be arranged between the plurality of battery cells 68 and the battery cell support surface 52. The interface layer 70 can be in the form of a thermal interface material (TIM) layer or an adhesive material that binds the plurality of battery cells 68 to the battery cell support surface 52.

[0038] Referring to Figure 3 and Figure 4 and continuing to refer to Figure 2 , a heat exchange member or cold plate 80 is coupled to the housing 50. The heat exchange member 80 includes a bottom plate 84, and the bottom plate 84 can be an outer surface (not separately marked) of the vehicle 10. Thus, the bottom plate 84 is substantially planar. The bottom plate 84 includes a first edge 90, a second edge 92 that is opposite to and substantially parallel to the first edge 90. The bottom plate 84 also includes a first side edge 94 and a second side edge 96 that is opposite to and substantially parallel to the first side edge 94. The first side edge 94 and the second side edge 96 extend between the first edge 90 and the second edge 92 and are connected to the first edge 90 and the second edge 92.

[0039] In a non-limiting example, a first reinforcing member 100 ( Figure 5 ) extends along the second side edge 96, and a second reinforcing member 102 extends along the first side edge 94. Referring to Figure 5 and continuing to refer to Figure 3 and 4, the first reinforcing member 100 includes a first end 104 and a second end 106 opposite the first end 104. Similarly, the second reinforcing member 102 includes a first end portion 108 and a second end portion 110 opposite the first end 104. A plurality of reinforcing elements 114 extend between the first reinforcing member 100 and the second reinforcing member 102 and connect the first reinforcing member 100 and the second reinforcing member 102.

[0040] In a non-limiting example, one of the plurality of reinforcing elements 114 extends between the first end 104 of the first reinforcing member 100 and the first end portion 108 of the second reinforcing member 102 and connects the first end 104 of the first reinforcing member 100 and the first end portion 108 of the second reinforcing member 102. Another of the plurality of reinforcing elements 114 extends between the second end 106 of the first reinforcing member 100 and the second end portion 110 of the second reinforcing member 102 and connects the second end 106 of the first reinforcing member 100 and the second end portion 110 of the second reinforcing member 102. The remaining reinforcing elements of the plurality of reinforcing elements 114 are spaced substantially evenly along and between the first edge 90 and the second edge 92, thereby forming a plurality of channels 120. In a non-limiting example, the selected reinforcing elements of the plurality of reinforcing elements 114 include a first recess 124 and a second recess 126.

[0041] According to a non-limiting example, the heat exchange member 80 supports the cooling system 130. The cooling system 130 includes a plurality of expandable sacs 134 that receive a quantity of cooling fluid. Each of the plurality of expandable sacs 134 includes a cooling fluid inlet 136 and a cooling fluid outlet 138. In a non-limiting example, the cooling fluid enters the cooling fluid inlet 136 and causes each of the plurality of expandable sacs 134 to expand into contact with the battery cell support surface 52. This contact establishes a heat exchange relationship between the cooling fluid and the plurality of battery cells 68 resting on the battery cell support surface 52. In a non-limiting example, each of the plurality of expandable sacs 134 is disposed in a corresponding one of the plurality of channels 120. At this time, it should be understood that although each of the plurality of channels 120 is shown as including a single expandable sac of the plurality of expandable sacs 134, the number of expandable sacs 134 in each channel 120 can vary according to cooling requirements and battery assembly dimensions.

[0042] In a non-limiting example, a cooling fluid supply system 140 is connected to a plurality of inflatable bladders 134. The cooling fluid supply system 140 includes an inlet manifold 144 that includes an inlet conduit 146 connected to a cooling fluid inlet 136 of each of the plurality of inflatable bladders 134. The cooling fluid supply system 140 further includes an outlet manifold 148 that includes an outlet conduit 150 connected to a cooling fluid outlet 138 of each of the plurality of inflatable bladders 134.

[0043] In a non-limiting example, cooling fluid flows from a cooling fluid supply tank (not shown) into the inlet manifold 144. The cooling fluid passes through the inlet conduit 146, causing each of the plurality of inflatable bladders 134 to expand and inflate. The cooling fluid absorbs heat from the plurality of battery cells 68 and flows via the outlet manifold 148 to a heat exchanger (also not shown). The cooling fluid can then return to the cooling fluid supply tank. At this time, it should be understood that the cooling fluid can be a liquid, a gas, or a multiphase fluid. Additionally, it should be understood that valves can be arranged at the cooling fluid inlet 136 and / or the cooling fluid outlet 138 of each of the plurality of inflatable bladders 134 to control the movement of the cooling fluid.

[0044] Reference Figure 6 , the heat exchange member 80 can include a bottom plate 154 that includes a non-planar surface 156. The non-planar surface 156 includes a plurality of protrusions 160 extending between a first edge 90 and a second edge 92. The protrusions 160 extend into each of the channels 120 toward the battery cell support surface 52. The plurality of protrusions 160 reduces the overall volume of each of the plurality of channels 120, thereby reducing the amount of cooling fluid required to inflate each of the plurality of inflatable bladders 134 to ensure good contact and an active heat exchange interface.

[0045] In a non-limiting example, each of the plurality of reinforcing elements 114 can also be used as Figure 7 and Figure 8The exhaust discharge duct 164 shown in [reference]. That is, each of the plurality of reinforcing elements 114 may have a hollow cross-section that defines an exhaust passage 166 fluidly connected to the internal region 58 via a plurality of exhaust channels or openings 170. The exhaust channels 170 are formed in the battery cell support surface 52 and extend into and are connected to the exhaust discharge duct 164 in each of the plurality of reinforcing elements 114. Each battery cell 68 includes an exhaust opening (not shown) aligned with a corresponding exhaust passage in the exhaust passageway 170. A seal (also not shown) is provided between each battery cell 68 and the battery cell support surface 52 at each of the plurality of exhaust channels 170. The heat exchange member 80 may be provided with an air moving device (not shown) that creates a positive pressure in the internal region 58 or a negative pressure in each exhaust discharge duct 164 to remove gases that may be discharged from the plurality of battery cells 68 from the battery assembly 38.

[0046] The terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Unless the context clearly dictates otherwise, the term "or" means "and / or". References throughout the specification to "aspect" mean that a particular element (e.g., a feature, structure, step, or property) described in connection with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. Additionally, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0047] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, no intervening elements are present.

[0048] The terms "about" and "substantially" are intended to include the degree of error associated with a particular quantity measurement based on the equipment available at the time of filing the application. For example, "about" and / or "substantially" can include a range of ±8% or 5% or 2% of a given value.

[0049] Unless otherwise stated herein, all test standards are the most recent standards in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0050] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0051] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made and elements thereof may be replaced with equivalents without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from its basic scope. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed, but that it will include all embodiments falling within its scope.

Claims

1. A battery assembly, comprising: A housing, the housing including a battery cell support surface and a plurality of side walls, the plurality of side walls jointly defining an internal region; A plurality of battery cells, the plurality of battery cells being arranged in the internal region; A heat exchange member mounted to the housing, the heat exchange member including a bottom plate; and A cooling system disposed in the heat exchange member, the cooling system including an expandable bladder disposed between the battery cell support surface and the bottom plate, the expandable bladder selectively expanding with a cooling fluid to contact the battery cell support surface.

2. The battery assembly according to claim 1, further comprising a plurality of channels extending between the battery cell support surface and the bottom plate, wherein the expandable bladder includes a plurality of expandable bladders, each of the plurality of expandable bladders being disposed in a corresponding one of the plurality of channels.

3. The battery assembly according to claim 2, further comprising a cooling fluid supply system, the cooling fluid supply system including an inlet manifold and an outlet manifold, the inlet manifold having inlet ducts fluidly connected to each of the plurality of expandable bladders, the outlet manifold having outlet ducts fluidly connected to each of the plurality of expandable bladders.

4. The battery assembly according to claim 3, wherein the heat exchange member includes a first edge, a second edge opposite the first edge, a first side edge, and a second side edge opposite the first side edge, a first reinforcing member extending along the first edge, and a second reinforcing member extending along the second edge, the first reinforcing member and the second reinforcing member being coupled to the battery cell support surface and the bottom plate.

5. The battery assembly according to claim 4, further comprising a plurality of reinforcing elements, the plurality of reinforcing elements extending between and connected to the first reinforcing member and the second reinforcing member, each of the plurality of channels being defined by adjacent ones of the plurality of reinforcing elements.

6. The battery assembly according to claim 5, wherein a selected one of the plurality of reinforcing elements includes a first recess for receiving the inlet duct and a second recess for receiving the outlet duct.

7. The battery assembly according to claim 5, wherein each of the plurality of reinforcing elements includes an exhaust passage, and the battery cell support surface includes a plurality of exhaust passages fluidly connecting the internal region and the exhaust passage.

8. The battery assembly according to claim 2, wherein the battery cell support surface fluidly isolates the internal region from the plurality of expandable bladders.

9. The battery assembly according to claim 2, wherein the bottom plate includes a non-planar surface having a plurality of protrusions, each of the plurality of protrusions extending toward a corresponding one of the plurality of channels.

10. A vehicle, comprising: A body; A plurality of wheels supporting the body; An electric drive unit supported in the body; and And The battery assembly according to claim 1, the battery assembly being operably connected to the electric drive unit.

Images