Tray and system for accommodating at least one battery module, and method for cooling at least one battery module accommodated in system tray

Abstract

The invention relates to a tray for accommodating at least one battery module, said tray comprising a bottom wall and side walls defining a receiving space for said at least one battery module, and at least one coolant inlet and at least one coolant outlet, wherein at least one of the side walls and / or the bottom wall comprises: a plate-shaped base part, and a first thermoplastic material-based layer, preferably a polyolefin-based layer, particularly preferably a polyolefin-based film, attached to or arranged against the base part; and a second thermoplastic material-based layer, preferably a polyolefin-based layer, particularly preferably a polyolefin-based film, bonded to the first layer, at least one channel being provided between the first layer and the second layer for the flow of a coolant medium, wherein the channel is connected with the at least one coolant inlet and with the at least one coolant outlet such that a coolant medium can flow through the channel, and wherein an associated wall is oriented in the tray such that a second layer faces the receiving space. The invention also relates to a system for accommodating at least one battery module and to a method for cooling at least one battery module accommodated in a tray of the system.

Description

Technical Field

[0001] In one aspect, the present invention relates to a tray for accommodating at least one battery module. In another aspect, the present invention relates to a system for accommodating at least one battery module. In yet another aspect, the present invention relates to a method for cooling at least one battery module accommodated in a system tray. Background Technology

[0002] Typically, battery modules (such as lithium-ion battery modules) involve a significant risk of thermal runaway in the event of a localized failure in one of the battery cells. This localized failure can originate from mechanical shock (e.g., during an electric vehicle crash), dendrite formation and internal short circuits during overcharging, defects or impurities in the cell, or thermal abuse. In the event of thermal runaway, the battery module remains susceptible to reignition, making fire suppression extremely difficult and time-consuming. The tray / enclosure used for battery modules is typically metallic, for example, cast from aluminum.

[0003] One objective is to provide a tray for accommodating at least one battery module, which has an improved cooling device. Another objective of the invention is to provide a tray for accommodating at least one battery module, which has a cooling device, and which can be manufactured in a simple and cost-effective manner.

[0004] Another object of the present invention is to provide a tray for accommodating at least one battery module, wherein the chance of catastrophic thermal runaway in the event of battery cell failure can be effectively reduced. One object is to provide a tray for at least one battery module, wherein a localized response to battery cell failure is possible.

[0005] Another object of the present invention is to provide safe transport of batteries in, for example, aircraft, ships and other modes of transport, before installation and use or at the end of their lifespan. Summary of the Invention

[0006] One or more of the above-mentioned objectives are achieved by a tray according to aspects of the invention for accommodating at least one battery module, the tray comprising a bottom wall and side walls, and at least one coolant inlet and at least one coolant outlet, the bottom wall and side walls defining a receiving space for the at least one battery module, and

[0007] At least one of the sidewalls and / or the bottom wall comprises:

[0008] - Plate-shaped foundation components;

[0009] - A first layer based on a thermoplastic material, preferably a layer based on a polyolefin, particularly preferably a film based on a polyolefin, attached to or disposed against the base component; and a second layer based on a thermoplastic material, preferably a layer based on a polyolefin, particularly preferably a film based on a polyolefin, bonded to the first layer, wherein at least one channel is provided between the first and second layers for the flow of a coolant medium, wherein the channel is connected to the at least one coolant inlet and the at least one coolant outlet such that the coolant medium can flow through the channel, wherein the associated wall in the tray is oriented such that the second layer faces the receiving space.

[0010] In another aspect, the present invention relates to a system for accommodating at least one battery module, comprising:

[0011] - One or more trays according to any one of the preceding claims; and

[0012] - Cooling system, which includes:

[0013] - Supply lines, which are connected to the coolant inlet of each of the one or more trays;

[0014] - A discharge line, which is connected to the coolant outlet of each of the one or more trays; and

[0015] - A flow generating device, such as a pump, for generating a circulating flow of the coolant medium through the supply line, through the channel, and through the discharge line.

[0016] In another aspect, the present invention relates to a method for cooling at least one battery module housed in a tray of a system according to the invention, comprising:

[0017] - Using the flow generating device, the flow of coolant medium is driven through channels in the one or more trays.

[0018] Several preferred features of the present invention are disclosed below. These features are applicable to trays, systems, and methods according to the present invention.

[0019] The effect of the tray, system, and method according to the invention is that, due to the following construction: at least one of the sidewalls and / or the bottom wall has at least one channel disposed between a first thermoplastic-based layer and a second thermoplastic-based layer for the flow of coolant medium, a localized battery cell failure (which leads to (localized) overheating of the associated battery cell) causes localized melting of the second thermoplastic-based layer, thereby creating localized cracks (or perforations or openings or punctures) in the second thermoplastic-based layer near the location of the cell failure in the battery module. As a result, a spray of coolant medium immediately emerges from the channel, passes through the localized opening, and counteracts the battery cell, thereby locally reducing the temperature of the battery cell and acting as a passive heat dissipation device, similar to a localized fire extinguisher. This helps prevent further propagation of thermal runaway within the cell and consequently to other cells in the module and / or multiple modules, thus avoiding catastrophic failure.

[0020] A further effect of the tray, system, and method according to the invention is that a cost-effective, more sustainable, and easily manufactured cooling device is achieved due to the following construction: at least one of the sidewalls and / or the bottom wall has at least one channel disposed between a first thermoplastic-based layer and a second thermoplastic-based layer for the flow of a coolant medium. The use of relatively expensive metals such as aluminum, which have a high CO2 footprint, can be reduced or even completely avoided. Cooling the battery module via at least one of the bottom wall and / or sidewalls of the tray is an efficient way to cool the battery module. Attached Figure Description

[0021] The invention is described below with reference to the accompanying schematic diagrams, in which examples of the invention are shown, and wherein the same reference numerals denote the same or similar elements.

[0022] Figure 1a An isometric schematic diagram of an example of a tray according to aspects of the present invention is shown, wherein five battery modules are received in the receiving space of the tray. Figure 1b It shows Figure 1a The tray, wherein the receiving space of the tray is completely occupied by the battery module. Figure 1c It shows Figure 1a and 1b A schematic isometric view of the individual battery module receiving chamber of the tray.

[0023] Figure 2a A cross-section of an example of a channel structure on the sidewall of a tray is shown, the sidewall of which has channels disposed between a first thermoplastic-based layer and a second thermoplastic-based layer for the flow of a coolant medium. Figure 2b It shows Figure 2aThe isometric view shown shows a first thermoplastic-based layer and a second thermoplastic-based layer, each having at least one channel for the flow of a coolant medium.

[0024] Figure 3 A more detailed view of another example of a channel construction with channel sidewalls is shown, the channel having multiple channel branches disposed between the first thermoplastic-based layer and the second thermoplastic-based layer for the flow of coolant medium.

[0025] Figure 4 An isometric schematic diagram of another example of a tray according to aspects of the present invention is shown.

[0026] Figure 5 An isometric schematic diagram of another example of a tray according to aspects of the present invention is shown.

[0027] Figure 6 An isometric schematic diagram of another example of a tray according to aspects of the present invention is shown.

[0028] Figure 7 A close-up of a portion of one of the side walls, bottom wall, and / or one or more inner partitions of the tray according to aspects of the present invention is shown in the event of overheating of the battery module's cells.

[0029] Figure 8 An example of a system according to another aspect of the invention is illustrated.

[0030] Figure 9 An example of a method according to another aspect of the invention is illustrated schematically.

[0031] Figure 10a and 10b A test apparatus for testing the concepts of the system and method of the present invention is disclosed. Detailed Implementation

[0032] The invention is illustrated below with a detailed description. Unless otherwise defined or specified, all terms shall be construed as having the technical meaning as understood by those skilled in the art.

[0033] Unless otherwise specified, all parameter ranges include the endpoints of the range and all values ​​between the endpoints. When used in this specification and claims, the terms "comprise" and "comprising," and variations thereof, mean that the specified feature, step, or integer is included. These terms should not be construed as excluding the presence of other features, steps, or components.

[0034] A tray is defined as an open container with a bottom wall and side walls for accommodating multiple battery cells. The bottom wall is defined as the wall that closes the bottom surface of the tray and, together with the side walls, forms a receiving space. The side walls are defined as the walls that close the sides of the tray and, together with the bottom wall, form a receiving space. Typically, a tray has one bottom wall and four side walls, defining a rectangular receiving space.

[0035] The tray may have one or more inner partitions extending between opposing sidewalls and subdividing the receiving space into a plurality of individual battery module receiving chambers, each of the plurality of individual battery module receiving chambers being defined by a portion of the bottom wall and by one or more sidewalls and / or one or more inner partitions, wherein the one or more inner partitions comprise:

[0036] - Plate-shaped base components, and / or

[0037] - At least a first thermoplastic-based layer and at least a second thermoplastic-based layer bonded to the first layer, wherein at least one channel is provided between the first and second layers for the flow of a coolant medium, wherein the channel is connected to at least one coolant inlet and at least one coolant outlet such that the coolant medium can flow through the channel.

[0038] An inner wall or partition is defined as a wall / partition that subdivides the receiving space formed by the bottom wall and side walls. The inner wall / partition extends between opposing side walls. In an embodiment, at least two inner walls / partitions of the tray extend perpendicularly to each other, thereby subdividing the receiving space into at least four battery module receiving chambers in a matrix shape of at least two by at least two battery module receiving chambers. If several inner walls / partitions extend between other inner walls / partitions, then all inner walls / partitions in one direction are considered to extend between opposing side walls. The inner walls / partitions subdivide the receiving space into receiving chambers or cavities for receiving battery modules or battery cells. These receiving chambers can be arranged in a matrix form as follows: a series of parallel inner walls / partitions extending in a first direction between a first pair of opposing side walls, and a series of parallel inner walls / partitions extending in a direction perpendicular to the first series and between a second pair of opposing side walls, the second pair of opposing side walls being perpendicular to the first pair of opposing side walls.

[0039] A battery module is defined as a single battery cell or an assembly of multiple interconnected battery cells.

[0040] At least one of one or more inner walls / partitions may include a plate-like base component, wherein the plate-like base component includes a first thermoplastic-based layer and a second thermoplastic-based layer on both plate sides of the base component. This allows for cooling of the battery module on both sides of the associated inner wall / partition.

[0041] The plate side is defined as the plate-shaped side of the base component, opposite to the edge of the plate-shaped base component.

[0042] The channel may have multiple branches to allow the coolant medium to flow through these branches during use. This allows for better distribution of the coolant medium between the first and second thermoplastic-based layers, particularly over more than 70% of the surface of the second thermoplastic-based layer facing the receiving space to contact the battery module. A branch is defined as a sub-channel arising from the main channel.

[0043] The inner walls / partitions of the tray can extend perpendicularly to each other and can subdivide the receiving space into at least four battery module receiving chambers in a matrix shape of at least two by at least two battery module receiving chambers. Each of the plate-like base components of the inner walls / partitions may include a slot such that two plate-like base components can interlock perpendicularly to each other at any given time, wherein the first of the two plate-like base components extends through a slot in the second of the two plate-like base components, and wherein the second of the two plate-like base components extends through a slot in the first of the plate-like base components. A slot is defined as an opening or recess in the plate-like base component, preferably a narrow opening or recess, for receiving a portion of another plate-like base component.

[0044] An embodiment is conceivable in which the coolant inlet and coolant outlet are the same. An embodiment is conceivable in which, after coolant is added, the coolant inlet and / or coolant outlet are sealed during use. An embodiment is conceivable in which the coolant inlet and coolant outlet are the same, and are sealed during use after coolant is added. Such an embodiment with coolant sealed within a first and second layer is, for example, suitable for the safe transport of battery modules.

[0045] As described above, the present invention relates to a system comprising a cooling system including a supply line connected to a coolant inlet of a tray and a discharge line connected to a coolant outlet of the tray, and a flow generating device, such as a pump, for generating a circulating flow of coolant medium through the supply line, through a channel and the discharge line.

[0046] A coolant inlet is defined as an inlet present in the tray, allowing coolant medium to enter one or more channels within the tray. It is conceivable that the bottom wall and each side wall, and optionally each inner wall / baffle, have individual coolant inlets, or that a single coolant inlet is provided from the tray. A coolant outlet is defined as an outlet present in the tray, allowing coolant medium to exit one or more channels within the tray. It is conceivable that the bottom wall and each side wall, and optionally each inner wall / baffle, have individual coolant outlets, or that a single coolant outlet is provided from the tray.

[0047] The coolant can be present under pressure, which will exhibit a certain amount of elastic stretching of the thermoplastic-based layers, particularly the second thermoplastic-based layer. This will ensure improved contact with the battery cell and lower thermal contact resistance during use. The cooling system can be configured to pressurize the coolant medium, for example, at a pressure between 0.5 and 20 Barg. The thermoplastic-based layers are elastically stretched due to the pressurized coolant medium.

[0048] Coolant media are defined as media used for cooling. Examples of them are (pressurized) coolant fluids, such as coolant gas, coolant liquid, or mixtures of coolant liquid or gas. Additionally, coolant gels may be mentioned. Preferably, the coolant media is a mixture of water and ethylene glycol. Ethylene glycol is commonly used to lower the freezing point of water; it is not typically used in pure form because it is very viscous. For mixtures of water and ethylene glycol, there is a balance between viscosity (less ethylene glycol) and a lower freezing point (more ethylene glycol). The exact ratio of water to ethylene glycol can be determined by those skilled in the art and depends on the operating temperature and the desired viscosity. A mixture of about 1:1 water:ethylene glycol (about 50% ethylene glycol) is commonly used and is suitable for this invention.

[0049] The system may also include a coolant medium reservoir connected via a valve to a supply line or a discharge line, such that the coolant medium flows through the passage when the valve is opened. The coolant medium reservoir is defined as a reservoir containing coolant medium and optionally a fire extinguishing agent, located outside the tray.

[0050] Fire extinguishing agents are defined as agents that suppress fires, such as chemical compounds that interfere with free radicals (primarily hydrogen, hydroxyl, or oxygen radicals) present during the combustion phase of a flame, like potassium citrate. In cases where a battery pack not only exhibits thermal runaway but also eventually ignites and forms a fire, such fire extinguishing agents may also be present in addition to coolant media.

[0051] The system may include a pressure sensor for detecting a pressure drop in the channel caused by localized melting of a thermoplastic-based layer, which is caused by heat generated by a battery module in the tray. The pressure sensor may be connected to a valve such that the valve opens when the pressure sensor detects the pressure drop.

[0052] The coolant medium may comprise a pressurized coolant fluid, preferably a liquid coolant, or a pressurized mixture of liquid and gaseous coolant. Examples of coolant media are dielectric liquid coolants that do not cause short circuits when leaked; examples include transformer oil, perfluoroalkane, and pure water. Preferred coolant media comprise water and ethylene glycol, and optionally a fire extinguishing agent.

[0053] Using a cooling system, the coolant medium can be pressurized, causing the thermoplastic-based layer to be elastically stretched due to the pressurized coolant medium, thereby increasing heat transfer from the battery module to the coolant medium due to the increased contact between the second thermoplastic-based layer and the battery module.

[0054] The plate-like base components of the bottom wall, side walls, and optional inner wall / partition are preferably made of thermoplastic materials, such as polyolefins. However, the plate-like base components of the bottom wall, side walls, and optional inner wall / partition of the tray may also be made of metal, such as aluminum or other suitable metals. In other words, the system according to the invention can be applied to known trays / shells.

[0055] When using thermoplastic materials, this can be freely selected from the group consisting of: for example, polypropylene or thermally conductive polycarbonate with low specific gravity, UL94 V0 polyolefin compounds with high specific strength and specific stiffness, UL94 V0 high-flow engineering thermoplastic compounds with good adhesive compatibility for thin internal components, and any of the family of polyester compounds with low-temperature ductility for impact absorbers. LEXAN 945 and CYCOLOY 7240 are mentioned as examples of these. Thermoplastic materials may contain one or more of the following: additives and / or stabilizers such as antioxidants, UV stabilizers, pigments, dyes, adhesion promoters, and flame retardants such as organophosphate / ester compounds (e.g., piperazine pyrophosphate / ester, piperazine polyphosphate / ester and combinations thereof), mixtures and combinations of organophosphate compounds (e.g., phosphoric acid, melamine pyrophosphate / ester, melamine polyphosphate / ester, melamine phosphate / ester), and zinc oxide, and / or fillers such as fibers or talc. For example, fiber-filled polyolefins can be used as thermoplastic materials. Possible fiber materials may include at least one of glass, carbon, aramid, or plastic, preferably glass. The fiber length can be chopped, long, short, or continuous. Specifically, long glass fiber-filled polypropylene (e.g., STAMAX available from SABIC) TM It can be used as a thermoplastic material. Long fibers can be defined as having an initial fiber length of at least 3 mm before molding. For example, talc-filled PP can also be used because of its good shrinkage / warpage behavior.

[0056] The first and second thermoplastic-based layers can be made of the same material. Each of the first and second thermoplastic-based layers is individually, preferably both, a polyolefin-based layer, more preferably a polyolefin-based film. The polyolefin can be, for example, an ethylene-based polymer or a propylene-based polymer. The preferred peak melt temperature (T0) of the polyolefin is... p,mThe temperature is at least 100°C, preferably at least 120°C or at least 140°C, as determined according to ASTM D 3418 (2008).

[0057] The first and second thermoplastic-based layers can be layers based on polyvinyl halide polymers, preferably films based on polyvinyl halide polymers, such as polyvinyl chloride (PVC) material, which is a thermoplastic chloropolymer having repeating vinyl chloride units, or polyvinyl fluoride (PVF) material, which is a thermoplastic fluoropolymer having repeating vinyl fluoride units. The thermoplastic-based layers / films can also be one or more of the following materials: i) polyetherimide (PEI) (e.g., ULTEM) ® ), ii) Modified resins (e.g., NORYL) consisting of amorphous blends of polyphenylene oxide (PPO) or polyphenylene oxide (PPE) resin with polystyrene. ® iii) Polycarbonate (PC) (e.g., LEXAN®), iv) Semi-crystalline materials of polybutylene terephthalate (PBT) and / or polyethylene terephthalate (PET), optionally blended with polycarbonate (PC) (e.g., VALOX). ® (v) Polyamide (PA). Preferably, the thermoplastic material has a peak melt temperature (T0) of at least 100°C, preferably at least 120°C or at least 140°C. pm According to ASTM D3418 (2008), the test result was obtained.

[0058] The polyolefin-based layer can be selected from the group consisting of: biaxially oriented polypropylene (BOPP) film, biaxially oriented polyethylene (BOPE) film, or film comprising one or more layers, preferably at least a core layer and two outer layers.

[0059] Ethylene-based polymers may be, for example, ethylene homopolymers or copolymers of ethylene with one or more α-olefins, preferably wherein the α-olefin comprises 1-10 carbon atoms, more preferably wherein the α-olefin is selected from 1-butene, 1-hexene, or 1-octene. For example, an ethylene-based polymer may contain ≥80.0% by weight, preferably ≥90.0% by weight, more preferably ≥95.0% by weight, of a structural moiety derived from ethylene, relative to the total weight of the ethylene-based polymer. For example, an ethylene-based polymer may contain ≤20.0% by weight, preferably ≤10.0% by weight, more preferably ≤5.0% by weight, of a structural moiety derived from 1-butene, 1-hexene, or 1-octene.

[0060] Ethylene-based polymers can, for example, have a density of ≥870 kg / m³. 3 Preferred values ​​are ≥870 and ≤975 kg / m³. 3 More preferably ≥900 and ≤975 kg / m 3 Even more preferred is ≥945 and ≤970 kg / m3 The density was determined according to ASTM D792 (2008).

[0061] Ethylene-based polymers may, for example, have a melt mass flow rate of ≥0.1 and ≤10.0 g / 10 min, preferably ≥0.1 and ≤5.0 g / 10 min, more preferably ≥0.2 and ≤3.5 g / 10 min, as determined according to ASTM D1238 (2013) at 190°C under a load of 2.16 kg.

[0062] The polypropylene-based membrane may comprise a propylene homopolymer, a propylene-ethylene copolymer, or a propylene-ethylene-C4 terpolymer or a propylene-ethylene-C6 terpolymer, wherein the copolymer or terpolymer has an ethylene content of up to 4.0% by weight, for example between 3.0 and 4.0% by weight, or up to 1.5% by weight in another embodiment, based on the weight of the copolymer or terpolymer; wherein the homopolymer, copolymer, or terpolymer has: i) a Mw / Mn ratio in the range of 4.0 to 12, preferably 5.0 to 12, where Mw represents the weight-average molecular weight and Mn represents the number-average molecular weight, and wherein Mw and Mn are measured according to ASTM D6474-12; ii) an XS ratio in the range of 1.0 to 8.0% by weight, preferably 1.0 to 6.0% by weight, where XS represents the amount of xylene-soluble matter as measured according to ASTM D 5492-10; and iii) an ethylene content in the range of 1 to 10% by weight. Melt flow rate in the range of dg / min, measured according to ISO 1133-1 (2011) (2.16 kg / 230℃).

[0063] Polyolefin films can be, for example, bidirectionally oriented films (BO films), wherein the orientation is introduced in the solid state. For example, BO films can be... p,m Oriented at a temperature at least 10°C lower. The BO film may, for example, have a thickness of ≥50 and ≤500 μm, preferably ≥50 and ≤300 μm. The BO film may be oriented in the longitudinal direction to an orientation degree of ≥5.0 and ≤25.0. The BO film may be oriented in the transverse direction to an orientation degree of ≥5.0 and ≤25.0. The BO film may be oriented in both the longitudinal and transverse directions to an orientation degree of ≥5.0 and ≤25.0. In this context, the orientation degree is defined as the ratio of the film size after orientation to the film size before orientation in both the longitudinal and transverse directions. BO films can be produced by: casting melt extrusion film, cooling the film to a temperature higher than T... p,m The film is then stretched at a temperature at least 10°C lower, both longitudinally and transversely. Stretching can be performed simultaneously in both directions, or sequentially, first in the longitudinal direction and then in the transverse direction, or first in the transverse direction and then in the longitudinal direction.

[0064] The accompanying drawings are shown below in more detail.

[0065] Figure 1a and Figure 1b An isometric view of an example of a tray 100 according to aspects of the present invention is shown. The tray 100 is arranged to accommodate a plurality of individual battery modules 10 and includes a bottom wall 101 and side walls 103 defining a receiving space 105 for receiving the plurality of individual battery modules 10. The tray 100 has one or more inner walls / partitions 107 extending between opposing side walls 103 and subdividing the receiving space 105 into a plurality of individual battery module receiving chambers 111. Each battery module receiving chamber 111 is defined by a portion of the bottom wall 101 and by one or more side walls 103 and / or inner walls / partitions 107. The tray 100 also includes a coolant inlet 113 and a coolant outlet 115.

[0066] Figure 1a and Figure 1b An example of a tray 100 is shown, wherein the inner walls / partitions 107 of the tray 100 extend perpendicularly to each other, thereby subdividing the receiving space 105 into thirty-six battery module receiving chambers 111 in a matrix shape of six by six battery module receiving chambers 111. Figure 1a In the process, five battery modules 10 are received in the receiving space 105 of the tray 100, wherein... Figure 1b In the tray 100, all the individual battery module receiving chambers 111 of the receiving space 105 are occupied by individual battery modules 10.

[0067] Figure 1c A schematic isometric view of the individual battery module receiving chamber 111 of the tray is shown. The battery module 10 is placed into the battery module receiving chamber 111 from the top of the tray. Figure 1c It shows Figure 1a , 1b A portion of the unidentified sidewalls, bottom walls, and / or inner partitions. Each sidewall and each inner partition / wall of the tray comprises a plate-like base component (not shown) and one of the side sections 116. The bottom wall comprises a plate-like base component and a bottom section, such as bottom section 114. Although not shown, bottom section 114 in the bottom wall (not shown) may also be omitted. The bottom section 114 and the side section 116 are made of a first thermoplastic-based layer 22 attached to or abutting the base component and a second thermoplastic-based layer 24 bonded to the first layer 22, wherein at least one channel (not shown) is provided between the first and second layers for the flow of a coolant medium. The second layer 24 faces the receiving chamber 111. The channel is connected to at least one coolant inlet and at least one coolant outlet of the tray, allowing the coolant medium to flow through the channel. The channel may, for example, have the following characteristics to be discussed below. Figure 2a ,2b Or the structure shown in Figure 3.

[0068] Figure 2a A more detailed cross-section of an example of the construction of the sidewall 103' for a tray (not shown) according to aspects of the present invention is shown. Figure 2b A more detailed isometric view of a portion of sidewall 103' is shown. Sidewall 103' comprises a plate-like base component (not shown) and a first thermoplastic-based layer 122 attached to or abutting the base component. Figure 2b The first layer 122 is bonded to a second thermoplastic-based layer 124, wherein at least one channel 120 is provided between the first layer 122 and the second layer 124 for the flow of a coolant medium. The channel 120 has an inlet 126 and an outlet 128, allowing the coolant medium to flow through the channel 120 (made of...). Figure 2a (As indicated by the arrow in 2b). The relevant sidewall 103' is oriented in the tray such that the second layer 124 faces the receiving space, i.e., the battery module. A tray bottom wall (not shown) with the same construction may be provided, or a bottom wall without a passage may be provided. Alternatively, a bottom wall with... Figure 2a The diagram shows a tray bottom wall (not shown) and tray side walls (not shown) without channels. Channels 120 in the side wall 103' may be directly connected to the tray's coolant inlet and coolant outlet, or may be connected to the tray's coolant inlet and coolant outlet via one or more other channels 120 in the other side wall 103' and / or the bottom wall.

[0069] Figure 3 A more detailed view of another example of a channel configuration with a sidewall 103” of channel 220 is shown, the channel 220 having a first layer based on a thermoplastic material (such as...) Figure 2a , 2b Layer 122) and the second thermoplastic-based layer (such as Figure 2a , 2b Multiple channel branches 220', 220" between layers 124) are used for the flow of the coolant medium (by... Figure 3 (As indicated by the arrow in the diagram). During use, the coolant medium flows via multiple branches between inlet 226 and outlet 228. The tray for accommodating at least one battery module may have a bottom wall and / or at least one side wall, which has… Figure 2a and 2b Alternatively, as shown in diagram 3, a channel is disposed between a first thermoplastic-based layer and a second thermoplastic-based layer for the flow of a coolant medium, wherein the channel may be connected to at least one coolant inlet of the tray and at least one coolant outlet of the tray, such that the coolant medium may flow through the channel.

[0070] Figure 4 Another example of tray 200 is shown. Tray 200 has two inner partitions 207 that extend between opposing sidewalls 203 and subdivide the receiving space into four separate battery module receiving chambers 211, each receiving chamber 211 being defined by a portion of the bottom wall 201 and by the sidewalls 203 and the inner partitions 207. Each inner partition 207 and each sidewall 203 includes: plate-shaped base components 207a, 203a; and at least a first thermoplastic-based layer 222 attached to or abutting against the plate portions of the base components 207a, 203a of each inner partition 207 and each sidewall 203; and at least a second thermoplastic-based layer 224, wherein the second layer 224 is bonded to the first layer 222, wherein at least one channel is provided between the first and second layers for the flow of a coolant medium, wherein the channel is connected to at least one coolant inlet 213 and at least one coolant outlet 215, allowing the coolant medium to flow through the channel. The plate portions of the base components 207a, 203a of each inner partition 207 and each sidewall 203 constitute approximately half of the entire surface of the plate-shaped base component facing the receiving space 205 of the tray 200. The bottom wall 201 may have a similar construction to the inner partition 207 / side wall 203, having four bottom wall regions (not shown). The channels of the individual battery module receiving chambers 211 may be interconnected, and each receiving chamber may have its own coolant inlet and outlet (not shown), but it is also possible that the channels of the four battery module receiving chambers 211 may be interconnected, and the tray 200 has a single coolant inlet 213 and a single coolant outlet 215 for interconnection channels.

[0071] Each inner partition 207 includes a plate-shaped base component 207a, which has channels on both sides of the base component 207a between a first thermoplastic-based layer 222 and a second thermoplastic-based layer 224 for the flow of coolant medium. Figure 4 In the illustrated embodiment, each battery module receiving chamber 211 has at least four sides provided with channels between a first thermoplastic-based layer 222 and a second thermoplastic-based layer 224 for the flow of a coolant medium. However, channels may also be provided on one, two, or three sides, while other sides (not shown) are not provided with channels, such that these other sides contain the base components 203a, 207a without layers 222, 224.

[0072] The plate-shaped base component 207a of the inner partition 207 may each include one or more slots (not shown) such that the two inner partitions 207 can be interlocked perpendicularly to each other at any time, wherein the first of the two partitions 207 extends through the slot in the second of the two partitions 207, and wherein the second of the two partitions 207 extends through the slot in the first of the partitions 207.

[0073] Figure 5 It shows relative to Figure 4 The tray 300 is an alternative embodiment of the tray 200 shown. The tray 300 also has two inner partitions 307 extending between opposing sidewalls 303 and subdividing the receiving space 305 into four separate battery module receiving chambers 311, each defined by a portion of the bottom wall and by the sidewalls and / or the inner partitions. Each inner partition 307 includes a first thermoplastic-based layer 380 and a second thermoplastic-based layer 382 bonded to the first layer 380. A channel is provided between the first layer 380 and the second layer 382 for the flow of a coolant medium, wherein the channel is connected to at least one coolant inlet 313 and at least one coolant outlet 315, allowing the coolant medium to flow through the channel. The inner partitions 307 do not have… Figure 4 The tray 200 shown has a plate-like base component. Therefore, both the first layer 380 and the second layer 382 face the battery module receiving chamber 311. Each sidewall 303 and / or bottom wall 301 includes: a plate-like base component 303a and a first thermoplastic-based layer 322 attached to or abutting the base component 303a, and a second thermoplastic-based layer 324 bonded to the first layer 322, wherein at least one channel is provided between the first layer 322 and the second layer 323 for the flow of a coolant medium, wherein the channel is connected to at least one coolant inlet 313 and at least one coolant outlet 315, allowing the coolant medium to flow through the channel, wherein the associated wall is oriented in the tray such that the second layer 324 faces the receiving space 305, particularly the battery module receiving chamber 311. The channels of the individual battery module receiving chambers 311 may be interconnected, and each receiving chamber 311 may have its own coolant inlet and outlet (not shown). However, it is also possible that the channels of the four battery module receiving chambers 311 may be interconnected, and the tray 300 may have a single coolant inlet 313 and a single coolant outlet 315 for interconnection channels. The bottom wall 301 may have a similar construction to the side wall 303.

[0074] Figure 6A tray 400 with an undivided receiving space 405 is shown as an alternative embodiment for providing a battery module receiving chamber. Each sidewall 403 and bottom wall 401 includes a plate-like base component 403a and a first thermoplastic-based layer 422 attached to or abutting the base component 403a, and a second thermoplastic-based layer 424 bonded to the first layer 422. At least one channel for the flow of a coolant medium is provided between the first layer 422 and the second layer 423, wherein the channel is connected to at least one coolant inlet 413 and at least one coolant outlet 415, allowing the coolant medium to flow through the channel. The associated wall is oriented in the tray such that the second layer 424 faces the receiving space 405. The channels may be interconnected, and the tray 400 may have a single coolant inlet 413 and a single coolant outlet 415 for interconnecting channels. Figure 6 In the illustrated embodiment, the receiving space 405 of the tray has at least four sides provided with channels between the first thermoplastic-based layer 422 and the second thermoplastic-based layer 424 for the flow of coolant medium. However, channels may also be provided on one, two, or three sides, wherein other sides (not shown) are not provided with channels, such that these other sides contain the base component 403 without layers 422, 424.

[0075] Figure 7 A close-up of a portion of one of the aforementioned sidewalls, bottom wall, and / or one or more inner partitions of trays 100; 200; 300; 400 is shown in the event of cell overheating in battery module 10. In addition to being arranged to cool battery module 10 via one of the sidewalls, bottom wall, and / or one or more inner partitions, in the event of cell overheating in battery module 10, one of the sidewalls, bottom wall, and / or one or more inner partitions is arranged as an internal spray system, which generates a spray of coolant medium 143 flowing through channel 120. For example, coolant medium 143 contains water and ethylene glycol, and optionally a fire extinguishing agent. Localized cell failure causing overheating of the relevant cell results in localized melting of one of the second layers 124; 224; 324; 424 or layers 380, 382, ​​thereby creating a localized perforation 141 in one of the second thermoplastic-based layers 124; 224; 324; 424 or layers 380, 382. As a result, coolant spray 143 immediately emerges from wall channel 120, passes through perforation 141 and counteracts the battery cell, thereby locally cooling the battery and helping to prevent thermal runaway.

[0076] The first thermoplastic-based layer and the second thermoplastic-based layer may be attached / bonded to each other in any manner known to those skilled in the art, such as heat stake, heat sealing, laser, or even ultrasound. Preferably, a channel 120 or a channel 220, 220', 220' is provided between the first thermoplastic-based layer and the second thermoplastic-based layer.

[0077] The first layer, based on a thermoplastic material, can be attached / bonded to the plate-like base component of the relevant wall by any means known to those skilled in the art, such as adhesive hot rods, heat sealing, laser, or even ultrasonic waves. The structure formed by the first and second layers can also be arranged in the tray without attaching the first layer to the plate-like base component. It is conceivable that this arrangement has sufficient dimensional stability when coolant or a temporary fluid (e.g., air) is pumped into the channel formed between the first and second layers without attachment to the plate-like base component.

[0078] Figure 8An example of a system 20 according to another aspect of the invention is schematically shown. System 20 is arranged to house a battery module 10 (not shown) and includes one or more trays of the present disclosure, such as tray 100 (or trays 200 / 300 / 400) according to aspects of the invention, and a cooling system 21. Cooling system 21 includes: a supply line 23 connected to a coolant inlet 113 of each of the one or more trays 100; a discharge line 25 connected to a coolant outlet 115 of each of the one or more trays 100; and a flow generating device 27, such as a pump, for generating a circulating flow of coolant medium through the supply line 23, through channels 120; 220, 220', 220' and the discharge line 25; system 20 also includes a coolant medium reservoir 29 and / or an external connection 13 for a fire responder, connected via a valve 11 to the supply line 23 or the discharge line 25 such that coolant medium 143 flows through channel 120 when valve 11 is opened. In the event of a localized battery cell failure leading to overheating of the relevant cell, localized melting occurs in one of layers 124; 224; 324; 424; 332, 334 or layers 380, 382, ​​resulting in a localized perforation 141 in one of layers 124; 224; 324; 424; 332, 334 or layers 380, 382. Coolant spray 143 and optional fire extinguishing agent 143 immediately emerge from channel 120, pass through perforation 141 and counteract the battery cell, thereby providing localized cooling and helping to prevent thermal runaway. System 20 also includes a pressure sensor 15 for detecting a pressure drop in channel 120 caused by partial melting of one of the thermoplastic-based layers 124; 224; 324; 424; 332, 334 or layers 380, 382, ​​which is caused by heat generated by the battery module 10 in tray 100. The pressure sensor 15 is communicatively connected to valve 11 such that valve 11 opens when the pressure sensor detects a pressure drop. Cooling system 21 is configured to pressurize a coolant medium, causing the thermoplastic-based layers to be elastically stretched due to the pressurized coolant medium.

[0079] In an embodiment of a system for accommodating at least one battery module, the system will have a stagnant cooling system comprising: one or more trays according to the invention, wherein, after the addition of coolant, the coolant inlet and coolant outlet (which may be the same) are sealed.

[0080] Figure 9An example of method 550 according to another aspect of the invention is illustrated. Method 550 is arranged for cooling a plurality of battery modules 10 housed in a tray 100 of a system 20 according to the invention. Method 550 includes a driving step 551: using a flow generating device 27, driving the flow of a coolant medium and optionally a fire extinguishing agent through channels 120 in one or more trays 100. The coolant medium comprises a pressurized coolant fluid, preferably a coolant liquid or a pressurized mixture of coolant liquid and gas. For example, the coolant medium comprises water and ethylene glycol and optionally a fire extinguishing agent. Using a cooling system 21, the coolant medium is pressurized such that the thermoplastic-based layers are elastically stretched due to the pressurized coolant medium, thereby increasing heat transfer from the battery modules 10 to the coolant medium due to increased contact between layers 124; 224; 324; 424; 332, 334 or layers 380, 382 and the battery modules 10.

[0081] To test the operation of the system and method of the present invention, the following proof-of-concept test was conducted. In this proof-of-concept test, specialized testing equipment was used instead of the tray 100 according to the present invention.

[0082] This testing equipment is in Figure 10a , 10b As shown in the diagram. The dedicated device 40 consists of a support plate 41 made of thermoplastic material, which has dimensions of 305 mm × 305 mm. This support plate 41 simulates the plate-like base component of the tray disclosed herein. The thermoplastic support plate 41 is 4 mm thick and is made of polypropylene (available from SABIC's STAMAX™) filled with long glass fibers. To simulate channel 120, an off-the-shelf thermoplastic bag 42 is used. This thermoplastic bag 42 is made of a 51-micron-thick layer based on thermoplastic material and has dimensions of 305 mm × 229 mm. The thermoplastic bag 42 is available from Cole-Palmer® (ESS GD 0912-7000 sampling bag with combination valve, 3L) and is a gas sampling bag made of 2-micron-thick Tedlar® material with a solid seam. Thermoplastic bag 42 includes a polypropylene combination valve (3 / 16" OD on / off lever) and an integrated PTFE silicone diaphragm. Thermoplastic bag 42 has a 3L volume and includes valves for attaching the bag to its inlet and outlet. (DuPont) TMThe Tedlar® material is a polyvinyl fluoride (PVF) material (which is a thermoplastic) with a melting point close to 190°C. The inlet of the thermoplastic bag 42 is attached to a supply line 43 (garden hose) via a pressure regulator 44 to supply regular water as the coolant medium 143. The thermoplastic bag 42 is connected to the water hose via a regulator with pressure control between 35-70 kPa. The thermoplastic bag 42 is then placed on top of a support plate 41 and clamped in place using four aluminum metal strips 45, which allows the formation of five expansion sections containing the pressurized coolant medium 143. These five expansion sections simulate channel 120. The metal strips 45 are 6.35 mm thick, 6.35 mm wide, and 305 mm long, and are spaced approximately 70 mm apart. These strips 45 are clamped using eight 2-inch QUICK-GRIP resin spring clips (not shown), one at each end of each strip. After securing the thermoplastic bag 42 to the support plate 41, a flame torch 46 was used to simulate thermal runaway of the battery module 10. The flame torch 46 was an air-fed methane flame torch, with its flame and distance adjusted to achieve a surface temperature of approximately 800°C. The flame torch 46 was held at a distance of approximately 12 cm from the thermoplastic bag 42, and within seconds of heating the thermoplastic bag 42, localized perforations 141 were achieved through localized melting of the thermoplastic bag, resulting in a significant spraying of the coolant medium 143. This proof-of-concept test clearly demonstrates the effectiveness of the system and method according to the invention.

[0083] In practicing the invention claimed, those skilled in the art can understand and implement other variations of the disclosed embodiments from a study of the drawings, disclosure, and appended claims. The scope of the invention is defined by the appended claims. One or more objects of the invention are achieved by the appended claims.

[0084] An example of variation is: a tray for accommodating at least one battery module, the tray comprising a bottom wall and side walls and at least one inlet, the bottom wall and side walls defining a receiving space for the at least one battery module, wherein at least one of the side walls and / or the bottom wall comprises:

[0085] - Plate-shaped foundation components;

[0086] A first layer based on a thermoplastic material, preferably a polyolefin-based layer, particularly preferably a polyolefin-based film, is attached to or disposed against the base component; and a second layer based on a thermoplastic material, preferably a polyolefin-based layer, particularly preferably a polyolefin-based film, is bonded to the first layer, wherein at least one channel for fluid is provided between the first and second layers, wherein the channel is connected to the at least one inlet so that fluid can enter the channel, for example, by filling the channel with fluid, wherein the associated walls in the tray are oriented such that the second layer faces the receiving space. Optionally, the tray also includes at least one outlet, wherein the channel is connected to the at least one outlet so that fluid, such as a coolant medium, can flow through the channel. The tray described in this paragraph may also be combined with other features / aspects disclosed herein.

[0087] List of reference numerals

[0088] 10: Battery Module

[0089] 11: Valve

[0090] 13: External connection for fire responder

[0091] 15: Pressure sensor

[0092] 20: System

[0093] 21: Cooling System

[0094] 22: The first layer based on thermoplastic materials

[0095] 23: Supply pipeline

[0096] 24: Second layer based on thermoplastic material

[0097] 25: Discharge pipeline

[0098] 27: Flow generating device

[0099] 29: Coolant medium reservoir

[0100] 40: Testing equipment

[0101] 41: Support plate

[0102] 42: Thermoplastic bags

[0103] 43: Water connector

[0104] 44: Pressure Regulator

[0105] 45: Metal strip

[0106] 46: Flame torch

[0107] 100: Pallet

[0108] 101: Bottom wall

[0109] 103: Sidewall

[0110] 103': Sidewall

[0111] 103'': Sidewall

[0112] 105: Receiving Space

[0113] 107: Inner wall / partition

[0114] 111: Battery module receiving chamber

[0115] 113: Coolant Inlet

[0116] 115: Coolant Outlet

[0117] 114: Bottom Section

[0118] 116: Side Section

[0119] 120: Channel

[0120] 122: The first layer based on thermoplastic materials

[0121] 124: Second layer based on thermoplastic material

[0122] 126: Entrance

[0123] 128: Exports

[0124] 141: Perforation

[0125] 143: Coolant medium

[0126] 200: Pallet

[0127] 201: Bottom wall

[0128] 203: Sidewall

[0129] 203a: Plate-shaped foundation components

[0130] 205: Receiving Space

[0131] 207: Inner partition

[0132] 207a: Plate-shaped foundation components

[0133] 211: Battery module receiving chamber

[0134] 213: Coolant Inlet

[0135] 215: Coolant Outlet

[0136] 220: Channel

[0137] 220' / 220'': Channel branch

[0138] 222: First layer based on thermoplastic material

[0139] 224: Second layer based on thermoplastic material

[0140] 226: Entrance

[0141] 228: Exports

[0142] 300: Pallet

[0143] 301: Bottom wall

[0144] 303: Sidewall

[0145] 303a: Plate-shaped foundation component

[0146] 305: Receiving Space

[0147] 307: Inner partition

[0148] 311: Battery module receiving chamber

[0149] 313: Coolant Inlet

[0150] 315: Coolant Outlet

[0151] 322: First layer based on thermoplastic material

[0152] 324: Second layer based on thermoplastic material

[0153] 380: The first layer based on thermoplastic materials

[0154] 382: Second layer based on thermoplastic material

[0155] 400: Pallet

[0156] 401: Bottom wall

[0157] 403: Sidewall

[0158] 403a: Plate-shaped foundation components

[0159] 405: Receive Space

[0160] 413: Coolant Inlet

[0161] 415: Coolant Outlet

[0162] 422: First layer based on thermoplastic material

[0163] 424: Second layer based on thermoplastic material

[0164] 550: Method

[0165] 501: Driving Steps

Claims

1. A tray for receiving at least one battery module, the tray comprising a bottom wall and side walls, and at least one coolant inlet and at least one coolant outlet, the bottom wall and side walls defining a receiving space for the at least one battery module. At least one of the sidewalls and / or the bottom wall comprises: - Plate-shaped foundation components; - A first layer based on a thermoplastic material, preferably a layer based on a polyolefin, particularly preferably a film based on a polyolefin, attached to or disposed against the base component; and a second layer based on a thermoplastic material, preferably a layer based on a polyolefin, particularly preferably a film based on a polyolefin, bonded to the first layer, wherein at least one channel is provided between the first and second layers for the flow of a coolant medium, wherein the channel is connected to the at least one coolant inlet and the at least one coolant outlet such that the coolant medium can flow through the channel, wherein the associated walls are oriented in the tray such that the second layer faces the receiving space.

2. The tray of claim 1, wherein the tray has one or more inner partitions extending between opposing sidewalls and subdividing the receiving space into a plurality of individual battery module receiving chambers, each of the plurality of individual battery module receiving chambers being defined by a portion of the bottom wall and by one or more sidewalls and / or one or more inner partitions, wherein the one or more inner partitions comprise: - Plate-shaped base components, and / or - at least a first layer based on a thermoplastic material, preferably a layer based on a polyolefin, particularly preferably a film based on a polyolefin; and at least a second layer based on a thermoplastic material, preferably a layer based on a polyolefin, particularly preferably a film based on a polyolefin, bonded to the first layer, wherein at least one channel is provided between the first layer and the second layer for the flow of a coolant medium, wherein the channel is connected to the at least one coolant inlet and the at least one coolant outlet such that the coolant medium can flow through the channel.

3. The tray according to claim 2, wherein the plate-shaped base component comprises the first thermoplastic-based layer and the second thermoplastic-based layer on both plate sides of the base component.

4. The tray according to claim 2 or 3, wherein the partitions of the tray extending perpendicularly to each other subdivide the receiving space into at least four battery module receiving chambers in a matrix shape of at least two by at least two battery module receiving chambers.

5. The tray of claim 4, wherein each of the plate-shaped base members of the partition includes a slot such that the two plate-shaped base members can be interlocked perpendicularly to each other at any time, wherein the first of the two plate-shaped base members extends through the slot in the second of the plate-shaped base members, and wherein the second of the two plate-shaped base members extends through the slot in the first of the plate-shaped base members.

6. The tray according to any one of the preceding claims, wherein the channel has a plurality of branches such that the coolant medium flows through the plurality of branches during use.

7. The tray according to any one of the preceding claims, wherein the coolant inlet and the coolant outlet are the same.

8. The tray according to any one of the preceding claims, wherein the coolant inlet and the coolant outlet are sealed.

9. A system for accommodating at least one battery module, comprising: - One or more trays according to any one of the preceding claims; and - Cooling system, which includes: - Supply lines, which are connected to the coolant inlet of each of the one or more trays; - A discharge line, which is connected to the coolant outlet of each of the one or more trays; and - A flow generating device, such as a pump, for generating a circulating flow of the coolant medium through the supply line, through the channel, and through the discharge line.

10. The system of claim 9, further comprising a coolant medium reservoir connected via a valve to the supply line or to the discharge line such that the coolant medium flows through the passage when the valve is opened.

11. The system of claim 9 or 10, comprising a pressure sensor for detecting a pressure drop in the channel, the pressure drop being caused by localized melting of the second thermoplastic-based layer, the localized melting being caused by heat generated by the battery module in the tray, wherein the pressure sensor is connected to the valve such that the valve opens when the pressure sensor detects the pressure drop.

12. The system according to any one of claims 9-12, wherein the cooling system is configured to pressurize the coolant medium such that the thermoplastic-based layer is elastically stretched due to the pressurized coolant medium.

13. A method for cooling at least one battery module housed in a tray of a system according to any one of claims 9-12, comprising: - Using the flow generating device, the flow of coolant medium is driven through channels in the one or more trays.

14. The method of claim 13, wherein the coolant medium comprises a pressurized coolant fluid, preferably a coolant liquid, or a pressurized mixture of coolant liquid and gas. Preferably, the coolant medium comprises water and ethylene glycol, and optionally a fire extinguishing agent.

15. The method of claim 13 or 14, wherein the cooling system is used in which the coolant medium is pressurized such that the thermoplastic-based layer is elastically stretched due to the pressurized coolant medium, thereby increasing heat transfer from the battery module to the coolant medium due to the increased contact between the layer and the battery module.

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