Structural support assembly including inflatable member for electric vehicle battery system

Abstract

A battery assembly includes a housing having a plurality of sidewalls that collectively define an interior region. A plurality of battery cells are arranged in the interior region. A support assembly connected to the housing supports a plurality of battery cells. The support assembly includes a support plate, an outer structural plate, and a channeled cooling plate disposed between the support plate and the outer structural plate, and a plurality of channeled cooling plate inflation ports extending through the support plate toward the channeled cooling plate. The plurality of channeled cooling plate inflation ports introduce an amount of fluid into the support assembly to expand one or more portions of the channeled cooling plate.

Description

Technical Field

[0001] The present invention relates to the field of electric vehicles, and more particularly, to a structural support assembly having an inflatable member for an electric vehicle battery assembly. Background Art

[0002] Many new vehicles are being manufactured with electric propulsion systems. Whether fully electric or hybrid, these systems rely on electric motors powered by energy stored in a rechargeable energy storage system (RESS) or a battery pack consisting of multiple battery cells. During operation, the battery cells generate heat, which reduces battery efficiency. To remove this heat, many vehicles include cooling systems that circulate a cooling fluid or coolant in thermal contact with the battery cells.

[0003] In some cases, the cooling system includes a support plate disposed within the battery housing. The battery cells are placed on the support plate. Coolant passes through conduits disposed beneath the support plate in heat exchange relationship with the battery cells. The coolant absorbs heat from the battery cells, passes through a heat exchanger, and then circulates back through the support plate and conduits. The support plate is typically large enough to support multiple battery cells, thin enough to provide a good thermal interface, and strong enough to withstand contact with road surfaces and debris.

[0004] Support plates are typically formed using an extrusion or brazing process. Extruded support plates are typically thin, making them suitable for smaller form factors. Brazing support plates limits material selection, is time-consuming, and expensive. Therefore, it is desirable to provide a support plate for a battery assembly that is easy and cost-effective to manufacture while also being structurally robust enough to protect the battery cells from exposure to the road and / or road debris. Summary of the Invention

[0005] According to a non-limiting example, a battery assembly includes a housing having a plurality of sidewalls that collectively define an interior region. A plurality of battery cells are disposed within the interior region. A support assembly coupled to the housing supports the plurality of battery cells. The support assembly includes a support plate, an outer structural plate, and a channeled cooling plate disposed between the support plate and the outer structural plate, and a plurality of channeled cooling plate plenum ports extending through the support plate toward the channeled cooling plate. The plurality of channeled cooling plate plenum ports introduce a quantity of fluid into the support assembly to expand one or more portions of the channeled cooling plate.

[0006] In addition to one or more features described herein, a plurality of anchor members connect the channeled cooling plate to the support plate.

[0007] In addition to one or more features described herein, the channeled cooling plate includes one or more selectively expandable inflatable regions and one or more fixed regions.

[0008] In addition to one or more features described herein, each of the one or more selectively expandable inflation regions is defined between two of the plurality of anchoring members.

[0009] In addition to one or more features described herein, at least one of the one or more selectively expandable inflatable regions defines a cooling fluid passage.

[0010] In addition to one or more features described herein, at least one of the one or more selectively expandable inflatable regions defining the cooling fluid passage includes a cooling fluid inlet and a cooling fluid outlet.

[0011] In addition to one or more features described herein, the plurality of channeled cooling plate plenum ports define at least one of a cooling fluid inlet and a cooling fluid outlet.

[0012] In addition to one or more features described herein, a plurality of anchor elements secure the outer structural panel to the support panel.

[0013] In addition to one or more features described herein, the outer structural panel includes one or more selectively expandable inflatable segments.

[0014] In addition to one or more features described herein, a plurality of external structural panel inflation ports extend through the external structural panel toward the channeled cooling plate, the plurality of external structural panel inflation ports introducing a volume of fluid between the external structural panel and the channeled cooling plate to inflate one or more portions of the external structural panel.

[0015] According to a non-limiting example, a vehicle includes a body including a passenger compartment, a plurality of wheels, an electric drive unit supported by the body and operably connected to one or more of the plurality of wheels, and a battery assembly operably connected to the electric drive unit. The battery assembly includes a housing having a plurality of side walls that collectively define an interior region. A plurality of battery cells are arranged in the interior region. A support assembly connected to the housing supports the plurality of battery cells. The support assembly includes a support plate, an external structural plate, and a channeled cooling plate arranged between the support plate and the external structural plate, and a plurality of channeled cooling plate charging ports extending through the support plate toward the channeled cooling plate. The plurality of channeled cooling plate charging ports introduce a quantity of fluid into the support assembly to expand one or more portions of the channeled cooling plate.

[0016] In addition to one or more features described herein, a plurality of anchor members connect the channeled cooling plate to the support plate.

[0017] In addition to one or more features described herein, the channeled cooling plate includes one or more selectively expandable inflatable regions and one or more fixed regions.

[0018] In addition to one or more features described herein, each of the one or more selectively expandable inflation regions is defined between two of the plurality of anchoring members.

[0019] In addition to one or more features described herein, at least one of the one or more selectively expandable inflatable regions defines a cooling fluid passage.

[0020] In addition to one or more features described herein, at least one of the one or more selectively expandable inflatable regions defining the cooling fluid passage includes a cooling fluid inlet and a cooling fluid outlet.

[0021] In addition to one or more features described herein, the plurality of channeled cooling plate plenum ports define at least one of a cooling fluid inlet and a cooling fluid outlet.

[0022] In addition to one or more features described herein, a plurality of anchor elements secure the outer structural panel to the support panel.

[0023] In addition to one or more features described herein, the outer structural panel includes one or more selectively expandable inflatable segments.

[0024] In addition to one or more features described herein, a plurality of external structural panel inflation ports extend through the external structural panel toward the channeled cooling plate, the plurality of external structural panel inflation ports introducing a volume of fluid between the external structural panel and the channeled cooling plate to inflate one or more portions of the external structural panel.

[0025] The above features and advantages and other features and advantages of the present disclosure will become apparent when the following detailed description is read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Additional features, advantages, and details appear by way of example only in the following detailed description, which refers to the accompanying drawings, in which:

[0027] Figure 1 is a left side view of a vehicle including a rechargeable energy storage system (RESS) having a heat exchange member including a battery cell support surface and a chargeable cooling system according to a non-limiting example;

[0028] Figure 2 According to non-limiting examples Figure 1 A partial perspective view of the RESS;

[0029] Figure 3 By way of non-limiting example Figure 2A cross-sectional view of the battery cell support surface and the inflatable cooling system before inflation, taken along line 3-3;

[0030] Figure 4 After inflation and installation of the outer structural panels according to a non-limiting example Figure 3 a cross-sectional view of a battery cell support surface and an inflatable cooling system;

[0031] Figure 5 is a planar cross-sectional view of a battery cell support surface, an inflatable cooling system, and an inflatable external structural panel prior to inflation according to another non-limiting example; and

[0032] Figure 6 After inflation according to a non-limiting example Figure 5 Cross-sectional view of the battery cell support surface, inflatable cooling system, and inflatable external structural panel. DETAILED DESCRIPTION

[0033] 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 indicate the same or corresponding parts and features.

[0034] According to a non-limiting example, the vehicle Figure 1 10. Vehicle 10 includes a body 12 supported on a plurality of wheels 16. Body 12 partially defines a passenger compartment 20 having a seat 23 positioned behind an instrument panel 26. A steering controller 30 is disposed between seat 23 and instrument panel 26. Steering controller 30 is operated to control the orientation of selected ones of the plurality of wheels 16. Vehicle 10 includes an electric drive unit 34 that provides power to one or more of the plurality of wheels 16.

[0035] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed within the vehicle body 12 and provides power to the electric drive unit 34. In this regard, it should be understood that the location of the electric drive unit 34 and the battery assembly 38 may vary. Figure 2 As shown, the battery assembly 38 includes a housing 50 having a support assembly 52 and a plurality of side walls 54 that collectively define an interior region 58. 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 (not shown).

[0036] A plurality of battery cells 68 are arranged in the interior region 58 of the housing 50. Figure 4As shown, the battery cells 68 are placed on the support assembly 52 between the first crossbar 70, the second crossbar 72 and the third crossbar 74. The first crossbar 70, the second crossbar 72 and the third crossbar 74 form two adjacent groups 78 and 80 of battery cells 68. The crossbars 70, 72 and 74 can also serve as side walls of the housing 50. In the non-limiting example shown, each group 78 and 80 includes four columns of 47 battery cells 68. At this point, it should be understood that the number of groupings, the number of columns in each grouping, the orientation of each grouping, and the number of battery cells in each column can vary. In addition, although depicted as prismatic battery cells, the battery cells 68 can take various forms, including pouch-shaped battery cells and cylindrical battery cells.

[0037] refer to Figure 3 and Figure 4 , and continue to refer to Figure 2 , the support assembly 52 includes a support plate 92, an outer structural plate 94, and a bubble or channeled cooling plate 96. The channeled cooling plate 96 is disposed between the support plate 92 and the outer structural plate 94. The support plate 92 includes a first or battery cell support surface 100 and a second surface 102 opposite the first surface 100. In a non-limiting example, the support plate 92 can be formed from one of aluminum (e.g., 5xxx or 6xxx aluminum plate), magnesium, steel, and / or alloys thereof. As will be described in detail herein, the channeled cooling plate 96 is connected to the support plate 92.

[0038] The outer structural plate 94 includes a first or outer surface portion 107 and a second surface portion 109 opposite the first surface portion 107. The outer structural plate 94 serves as a slide plate or outer protective plate for the battery assembly 38 and can be formed from one of aluminum (e.g., 5xxx or 6xxx aluminum plate), magnesium, steel, and / or alloys thereof. The outer structural plate 94 can also be formed from a composite material. The outer structural plate 94 includes one or more first portions 112 adjacent to or nearly adjacent to the channeled cooling plate 96 and one or more second portions 114 spaced apart from the channeled cooling plate 96, thereby forming corresponding chambers 116 and 118.

[0039] The ducted cooling plate 96 is secured to the support plate 92 by a plurality of anchoring members 120. The anchoring members 120 may define weld beads, spot welds, fasteners, adhesives, sealants, etc. Similarly, the outer structural plate 94 is secured to the support plate 92 by a plurality of anchoring elements 122. The anchoring elements 122 may take the form of bolts that extend through the outer structural plate 94, the ducted cooling plate 96, and the support plate 92 and connect with the first crossbar 70, the second crossbar 72, and the third crossbar 74. The ducted cooling plate 96 includes one or more first segments 126 and one or more second segments 128, with the first segments 126 abutting or nearly abutting the second surface 102 of the support plate 92, as shown in FIG. Figure 3As shown, the second section 128 is not anchored to the support plate 92. Figure 4 shown.

[0040] In a non-limiting example, the support assembly 52 includes a first channeled cooling plate plenum port 130 and a second channeled cooling plate plenum port 132 disposed in the support plate 92. The first and second channeled cooling plate plenum ports 130 and 132 are mounted in the second segments 128 of the channeled cooling plate 96. The first channeled cooling plate plenum port 130 and the second channeled cooling plate plenum port 132 deliver pressurized fluid between the second surface 102 and the channeled cooling plate 96, causing each second segment 128 to expand, as shown. Figure 4 As shown. That is, each second segment 128 of the channeled cooling plate 96 defines a selectively expandable plenum region 136a, 136b, 136c, and 136d at each second segment 128. In a non-limiting example, the selectively expandable plenum regions 136a, 136b, 136c, and 136d can be fluidly connected to each other to form a network of cooling regions. Each anchoring member 120 creates a fixed region 140a, 140b, 140c, 140d, 140e, and 140f of the channeled cooling plate 96 at each first segment 126. The fixed regions 140a-140f are anchored to the channeled cooling plate 96, while the selectively expandable plenum regions 136a-136d form corresponding fluidly interconnected cooling fluid channels 144a, 144b, 144c, and 144d that direct cooling fluid in heat exchange relationship with the second surface 103 of the channeled cooling plate 96.

[0041] In a non-limiting example, the support assembly 52 includes a cooling fluid supply inlet 148 and a cooling fluid supply outlet 150 ( FIG. 1 ) that are fluidly connected to the cooling fluid passages 144 a - 144 d. Figure 2 ). In a non-limiting example, the first channeled cooling plate charge port 130 and the second channeled cooling plate charge port 132 can be removed after the channeled cooling plate 96 is charged. In another non-limiting example, the first channeled cooling plate charge port 130 and the second channeled cooling plate charge port 132 can be connected to the cooling fluid supply inlet 148 and the cooling fluid supply outlet 150 to define a cooling fluid inlet 152 and a cooling fluid outlet 154. With this arrangement, cooling fluid can flow through the battery assembly 38 below the support plate 92. By charging the channeled cooling plate 96 to form the cooling channels, the support assembly 52 is not only easier to manufacture, but also, due to the addition of the external structural plate 94, the support assembly 52 is protected from external loads, such as loads that may occur when the vehicle 10 hits a pothole or drives over various road debris.

[0042] exist Figure 5 and 6In another non-limiting example shown, the support assembly 52 may include an outer structural support plate 156 having a first selectively expandable inflatable segment 158a and a second selectively expandable inflatable segment 158b. Figure 3 and 5 The outer structural support panel 94 is shown fixed, and the outer structural support panel 156 can be expanded. In a non-limiting example, in addition to the first channeled cooling panel charging port 130 and the second charging port 132 provided in the support panel 92, the support assembly 52 includes a first outer structural panel charging port 162 and a second outer structural panel charging port 164 provided in the outer structural panel 156 ( Figure 6 ). The number and location of the external structure inflation ports may vary.

[0043] In a non-limiting example, the outer structural panel 156 is secured to the support plate 92 by a plurality of anchor members 166a, 166b, 166c, and 166d. A first selectively expandable inflatable segment 158a is defined between the anchor members 166a and 166b, and a second selectively expandable inflatable segment 158b is defined between the anchor members 166b and 166c. A first outer structural panel inflation port 162 and a second outer structural panel inflation port 164 deliver pressurized fluid between the outer structural panel 156 and the ducted cooling plate 96 to inflate the first selectively expandable inflatable segment 158a and the second selectively expandable inflatable segment 158b.

[0044] The expansion of the first and second selectively expandable inflatable segments 158a, 158b accommodates the expansion of the selectively expandable inflatable region 136 of the ducted cooling plate 96. By inflating the first and second selectively expandable inflatable segments 158a, 158b, the support assembly 52 is easier and less expensive to manufacture. That is, there is no need to purchase pre-formed external structural support panels.

[0045] The terms "a" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced item. The term "or" means "and / or" unless the context clearly indicates otherwise. References to "an aspect" throughout this specification mean that a particular element (e.g., feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in various aspects.

[0046] 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, there are no intervening elements present.

[0047] Unless otherwise indicated 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.

[0048] Unless defined otherwise, 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 belongs.

[0049] Although the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope thereof. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope of the present disclosure. Therefore, it is intended that the present disclosure is not limited to the particular embodiments disclosed, but is intended to include all embodiments falling within its scope.

Claims

1. A battery assembly comprising: a housing comprising a plurality of side walls that collectively define an interior region; a plurality of battery cells arranged in the interior region; as well as A support assembly connected to a housing supporting a plurality of battery cells, the support assembly including a support plate, an external structural plate, and a channeled cooling plate disposed between the support plate and the external structural plate, and a plurality of channeled cooling plate inflation ports extending through the support plate toward the channeled cooling plate, the plurality of channeled cooling plate inflation ports introducing a quantity of fluid into the support assembly to expand one or more portions of the channeled cooling plate. 2 . The battery assembly of claim 1 , further comprising a plurality of anchor members connecting the channeled cooling plate to the support plate.

3. The battery assembly according to claim 2, wherein: The channeled cooling plate includes one or more selectively expandable inflatable regions and one or more fixed regions.

4. The battery assembly according to claim 3, wherein: Each of the one or more selectively expandable inflation regions is defined between two of the plurality of anchoring members.

5. The battery assembly according to claim 3, wherein: At least one of the one or more selectively expandable inflatable regions defines a cooling fluid passage.

6. The battery assembly according to claim 5, wherein: At least one of the one or more selectively expandable inflatable regions defining the cooling fluid passage includes a cooling fluid inlet and a cooling fluid outlet.

7. The battery assembly according to claim 6, wherein: The plurality of channeled cooling plate plenum ports define at least one of the cooling fluid inlet and the cooling fluid outlet.

8. The battery assembly of claim 3, further comprising a plurality of anchor elements securing the outer structural plate to the support plate.

9. The battery assembly according to claim 3, wherein: The outer structural panel includes one or more selectively expandable inflatable segments.

10. The battery assembly according to claim 9 further includes a plurality of external structural plate inflation ports, which extend through the external structural plate toward the channeled cooling plate, and the plurality of external structural plate inflation ports introduce a certain amount of fluid between the external structural plate and the channeled cooling plate to expand one or more portions of the external structural plate.

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