System and method for thermal management of battery modules

Abstract

Battery module data is received from a battery module sensor. It is determined whether a cell abnormality has occurred among the cells of the battery module based on the battery module data. Based on the determination, a command is issued to a compression control system to place the battery module in an uncompressed position. The compression control system includes a first compression plate and a second compression plate. A plurality of battery cells are disposed between the first compression plate and the second compression plate. A compression mechanism coupled to the first compression plate and the second compression plate has a default compression position for holding the first compression plate and the second compression plate in a first spaced apart position and an uncompressed position for placing the first compression plate and the second compression plate in a second spaced apart position in response to a command. The first spaced-apart position is smaller than the second spaced-apart position.

Description

TECHNICAL FIELD

[0001] The technical field is generally related to vehicles, and more specifically to thermal management of battery modules of vehicles. BACKGROUND

[0002] Electric vehicles are typically powered by a battery system that includes a plurality of battery modules. Each battery module includes a plurality of battery cells. Examples of battery cells include, but are not limited to, pouch battery cells and prismatic battery cells. Occurrence of a battery cell anomaly in a battery cell of a battery module can cause cell-to-cell propagation of the battery cell anomaly to other battery cells in the battery module, resulting in thermal propagation in the battery module.

[0003] Accordingly, it is desirable to provide systems and methods for thermal management of battery modules in electric vehicles. Other desirable features and characteristics will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background. SUMMARY

[0004] A battery module thermal management system includes a processor and a memory communicatively coupled to the processor. The memory includes instructions that, when executed by the processor, cause the processor to receive, from at least one battery module sensor, battery module data associated with a first battery module, the first battery module including a plurality of battery cells; determine, based on the battery module data, whether a battery cell anomaly has occurred in at least one battery cell of the first battery module; and issue, based on the determination, a first command to a compression control system to place the first battery module in an uncompressed position. The compression control system includes a first compression plate disposed at a first end of the first battery module, a second compression plate disposed at a second end of the first battery module, wherein the second end of the first battery module is opposite the first end of the first battery module and the plurality of battery cells is disposed between the first compression plate and the second compression plate, and a compression mechanism coupled to the first compression plate and the second compression plate, the compression mechanism having a default compressed position to maintain the first compression plate and the second compression plate in a first spaced apart position and an uncompressed position to place the first compression plate and the second compression plate in a second spaced apart position in response to the first command, the first spaced apart position being less than the second spaced apart position.

[0005] In at least one embodiment, each of the plurality of battery cells includes a first side having a first planar surface and a second side having a second planar surface, wherein the second side is opposite the first side and the first side and the second side are parallel to the first compression plate and the second compression plate.

[0006] In at least one embodiment, the plurality of battery cells is one of a plurality of pouch battery cells and a plurality of prismatic battery cells.

[0007] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to: receive, from the at least one battery module sensor, battery module data associated with the first battery module, wherein the at least one battery module sensor includes at least one of a gas emission sensor, a module pressure sensor, and an acoustic emission sensor.

[0008] In at least one embodiment, the compression mechanism includes at least one compression rod having a first end coupled to the first compression plate and a second end coupled to the second compression plate via a spring; and a solenoid coupled to the spring, wherein upon activation of the solenoid, the spring is released from the compressed state to the uncompressed state, thereby moving the first compression plate and the second compression plate from the first spaced apart position to the second spaced apart position.

[0009] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor, upon determining that a battery cell anomaly has occurred in at least one battery cell of the first battery module: determine whether a state of charge (SOC) of the first battery module is greater than an SOC threshold; and based on the determination, issue a second command to the battery module SOC discharge system to lower the SOC of the first battery module below the SOC threshold.

[0010] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor, upon determining that a battery cell anomaly has occurred in at least one battery cell of the first battery module: issue a second command to the battery module state of charge (SOC) discharge system to lower the SOC of the first battery module in parallel with the compression control system placing the first battery module in the uncompressed position.

[0011] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor: determine whether a vehicle including the first battery module is coupled to a grid charging system; and issue a second command to the battery module SOC discharge system to lower the SOC of the first battery module by supplying energy from the first battery module back to the grid charging system.

[0012] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to issue a second command to the battery module SOC discharge system to lower the SOC of the first battery module by activating operation of a vehicle accessory of a vehicle including the first battery module and supplying energy from the first battery module to the vehicle accessory.

[0013] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to: determine whether the vehicle comprising the first battery module is parked; and issue a second command to the battery module SOC discharge system to reduce the SOC of the first battery module by activating operation of a propulsion system and a braking system of the vehicle and supplying energy from the first battery module to the propulsion system and the braking system.

[0014] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell abnormality has occurred in at least one battery cell of the first battery module: issue a second command to the battery module SOC discharge system to reduce the SOC of the first battery module by dissipating energy from the first battery module via a dedicated integrated resistor.

[0015] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell abnormality has occurred in at least one battery cell of the first battery module: determine whether the SOC of the first battery module is greater than a SOC threshold; and issue a second command to the battery module SOC discharge system to reduce the SOC of a battery system comprising a plurality of battery modules based on the determination, the plurality of battery modules comprising the first battery module.

[0016] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell abnormality has occurred in at least one battery cell of the first battery module, increase a flow of coolant to the first battery module.

[0017] In at least one embodiment, each of the plurality of battery cells is coated with an intumescent coating.

[0018] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell abnormality has occurred in at least one battery cell of the first battery module, generate a battery system abnormality notification for display on a display device of a vehicle comprising the first battery module.

[0019] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell abnormality has occurred in at least one battery cell of the first battery module, generate a battery system abnormality notification for transmission to a vehicle service center associated with a vehicle comprising the first battery module.

[0020] In at least one embodiment, a vehicle includes a plurality of battery modules including a first battery module; each of the plurality of battery modules includes an associated compression control system and an associated battery module SOC discharge system; and a memory includes further instructions that, when executed by the processor, cause the processor to: receive a vehicle event notification associated with the vehicle; issue a third command to the compression control system of each of the plurality of battery modules to place the battery module in an uncompressed position; and issue a fourth command to the battery module SOC discharge system associated with each of the plurality of battery modules to reduce the SOC of the battery module.

[0021] A method of thermal management of a battery module includes receiving, from at least one battery module sensor, battery module data associated with a first battery module, the first battery module including a plurality of battery cells; determining, based on the battery module data, whether a battery cell anomaly has occurred in at least one battery cell of the first battery module; and issuing, based on the determination, a first command to a compression control system to place the first battery module in an uncompressed position, wherein the compression control system includes: a first compression plate disposed at a first end of the first battery module; a second compression plate disposed at a second end of the first battery module, wherein the second end of the first battery module is opposite the first end of the first battery module and the plurality of battery cells are disposed between the first compression plate and the second compression plate; and a compression mechanism coupled to the first compression plate and the second compression plate, the compression mechanism having a default compressed position to maintain the first compression plate and the second compression plate in a first spaced apart position and an uncompressed position to place the first compression plate and the second compression plate in a second spaced apart position in response to the first command, the first spaced apart position being less than the second spaced apart position.

[0022] A vehicle including a battery module thermal management system includes a processor; and a memory communicatively coupled to the processor. The memory includes instructions that, when executed by the processor, cause the processor to: receive, from at least one battery module sensor, battery module data associated with a first battery module, the first battery module including a plurality of battery cells; determine, based on the battery module data, whether a battery cell anomaly has occurred in at least one battery cell of the first battery module; and issue, based on the determination, a first command to a compression control system to place the first battery module in an uncompressed position, wherein the compression control system includes: a first compression plate disposed at a first end of the first battery module; a second compression plate disposed at a second end of the first battery module, wherein the second end of the first battery module is opposite the first end of the first battery module, and the plurality of battery cells are disposed between the first compression plate and the second compression plate; and a compression mechanism coupled to the first compression plate and the second compression plate, the compression mechanism having a default compressed position to maintain the first compression plate and the second compression plate in a first spaced apart position, and an uncompressed position to place the first compression plate and the second compression plate in a second spaced apart position in response to the first command, the first spaced apart position being less than the second spaced apart position.

[0023] In at least one embodiment, the memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that the battery cell anomaly has occurred in the at least one battery cell of the first battery module: determine whether a state of charge (SOC) of the first battery module is greater than an SOC threshold; and issue, based on the determination, a second command to a battery module SOC discharge system to lower the SOC of the first battery module below the SOC threshold. BRIEF DESCRIPTION OF DRAWINGS

[0024] The exemplary embodiments will be described below with reference to the following drawings, in which like elements are referred to with like reference numerals, and in which:

[0025] Figure 1 is a functional block diagram of a vehicle including a battery module thermal management system in accordance with at least one embodiment;

[0026] Figure 2 is a functional block diagram of a controller including a battery module thermal management system in accordance with at least one embodiment;

[0027] Figure 3 is a flowchart representation of an exemplary method of thermal management of a battery module in accordance with at least one embodiment;

[0028] Figure 4 is a functional block diagram representation of a battery module including a compression control system in accordance with at least one embodiment;

[0029] Figure 5is a functional block diagram representation of a battery system including a dedicated integrated resistor according to at least one embodiment; and

[0030] Figure 6 is a flowchart representation of an exemplary method of thermal management of a battery module in response to a vehicle event according to at least one embodiment. DETAILED DESCRIPTION

[0031] The following detailed description is merely exemplary in nature and is not intended to limit the application and use. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, summary or the following detailed description. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the described functionality.

[0032] Embodiments of the disclosure can be described herein in terms of functional and / or logical block components and various processing steps. It should be appreciated that such block components can be realized by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the disclosure can employ various integrated circuit components, e.g., memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which can carry out a variety of functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments of the disclosure can be practiced with other systems than the system described herein and that the system described herein is merely one example embodiment of the disclosure.

[0033] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual operating components of the systems) can not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and / or physical couplings between the various elements. It should be noted that many alternatives or additional functional relationships or physical connections can be present in an embodiment of the disclosure.

[0034] Reference Figure 1 , shows a functional block diagram of a vehicle 10 including a battery module thermal management system 100 according to at least one embodiment. The vehicle 10 generally includes a chassis 12, a body 14, front wheels 16, and rear wheels 18. Although the vehicle 10 is depicted as a passenger car in the illustrated embodiment, the vehicle 10 can be other types of vehicles including trucks, sport utility vehicles (SUVs), and recreational vehicles (RVs).

[0035] In various embodiments, the vehicle body 14 is disposed on the chassis 12 and substantially encloses components of the vehicle 10. The vehicle body 14 and the chassis 12 can collectively form a frame. The wheels 16-18 are each rotationally coupled to the chassis 12 near a respective corner of the vehicle body 14.

[0036] In various embodiments, the vehicle 10 is an autonomous or semi-autonomous vehicle that is automatically controlled to transport passengers and / or cargo from one place to another. For example, in an exemplary embodiment, the vehicle 10 is a so-called Level 2, Level 3, Level 4, or Level 5 automation system. Level 2 automation refers to a vehicle that assists the driver in completing various driving tasks under the supervision of the driver. Level 3 automation refers to a vehicle that can take over all driving functions under certain conditions. All major functions are automated, including braking, steering, and acceleration. At this level, the driver can disengage completely until the vehicle tells the driver to take over. Level 4 systems indicate “high automation” and refer to a specific driving mode performance on all aspects of dynamic driving tasks with an automated driving system that is capable of achieving full-time performance on all aspects of dynamic driving tasks even if a human driver does not respond appropriately to an intervention request. Level 5 systems indicate “full automation” and refer to full-time performance on all aspects of dynamic driving tasks with an automated driving system under all road and environmental conditions that a human driver can manage.

[0037] As shown, the vehicle 10 generally includes a propulsion system 20, a transmission system 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one data storage device 32, at least one controller 34, and a communication system 36. The controller 34 is configured to implement an automated driving system (ADS). The propulsion system 20 is configured to generate power to propel the vehicle. In various embodiments, the propulsion system 20 can include an internal combustion engine, an electric machine such as a traction motor, a fuel cell propulsion system, and / or any other type of propulsion configuration. The transmission system 22 is configured to transfer power from the propulsion system 20 to the vehicle wheels 16-18 according to a selectable speed ratio. According to various embodiments, the transmission system 22 can include a stepped-ratio automatic transmission, a continuously variable transmission, or other suitable transmission. The braking system 26 is configured to provide braking torque to the vehicle wheels 16-18. In various embodiments, the braking system 26 can include a friction brake, a brake-by-wire brake, a regenerative braking system such as an electric machine, and / or other suitable braking system. In at least one embodiment, the battery module thermal management system 100 is communicatively coupled to the propulsion system 20 and the braking system 26.

[0038] The steering system 24 is configured to affect the position of the vehicle wheels 16. While depicted for illustrative purposes as including a steering wheel and steering column, the steering system 24 can not include a steering wheel and / or steering column in some embodiments contemplated within the scope of the present disclosure. The steering system 24 includes a steering column coupled to an axle 50 associated with the front wheels 16 by, for example, a rack and pinion or other mechanism (not shown). Alternatively, the steering system 24 can include a steer-by-wire system including an actuator associated with each front wheel 16.

[0039] The sensor system 28 includes one or more sensing devices 40a-40n that sense observable conditions of the external and / or internal environment of the vehicle 10. The sensing devices 40a-40n can include, but are not limited to, radar, lidar, global positioning systems, optical cameras, thermal cameras, ultrasonic sensors, and / or other sensors. In various embodiments, the sensor system 28 includes a biometric sensor system configured to sense occupant biometric data of one or more occupants of the vehicle 10. In various embodiments, the sensor system 28 includes a vehicle environment sensor system configured to sense vehicle environment data. In at least one embodiment, the battery module thermal management system 100 is communicatively coupled to the sensor system 28. In at least one embodiment, the sensor system 28 includes battery module sensors. Examples of battery module sensors include, but are not limited to, gas emission sensors, module pressure sensors, and acoustic emission sensors. The battery module sensors are configured to provide battery module data.

[0040] The vehicle dynamics sensors provide vehicle dynamics data including longitudinal speed, yaw rate, lateral acceleration, longitudinal acceleration, etc. The vehicle dynamics sensors can include wheel sensors that measure information related to one or more wheels of the vehicle 10. In one embodiment, the wheel sensors include a wheel speed sensor coupled to each of the wheels 16-18 of the vehicle 10. Additionally, the vehicle dynamics sensors can include one or more accelerometers (provided as part of an inertial measurement unit (IMU)) that measure information related to the acceleration of the vehicle 10. In various embodiments, the accelerometers measure one or more acceleration values of the vehicle 10 including lateral and longitudinal acceleration and yaw rate.

[0041] The actuator system 30 includes one or more actuator devices 42a-42n that control one or more vehicle features such as, but not limited to, the propulsion system 20, the transmission system 22, the steering system 24, and the braking system 26. In various embodiments, the vehicle features can further include internal and / or external vehicle features such as, but not limited to, doors, trunk, and cabin features such as air, music, lighting, etc. (not numbered).

[0042] The communication system 36 is configured to wirelessly communicate information to and from other entities 48, such as but not limited to other vehicles ("V2V" communications), infrastructure ("V2I" communications), remote systems, and / or personal devices. In an exemplary embodiment, the communication system 36 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods, such as a dedicated short-range communications (DSRC) channel, are also contemplated to be within the scope of the present disclosure. A DSRC channel refers to a one-way or two-way short-to-medium range wireless communication channel specifically designed for automotive use as well as a corresponding set of protocols and standards.

[0043] The data storage device 32 stores data for use in the ADS of the vehicle 10. In various embodiments, the data storage device 32 stores a defined map of a navigable environment. In various embodiments, the defined map can be predefined by and obtained from a remote system. For example, the defined map can be assembled by a remote system and communicated to the vehicle 10 (wirelessly and / or in a wired manner) and stored in the data storage device 32. It can be appreciated that the data storage device 32 can be part of the controller 34, separate from the controller 34, or part of the controller 34 and part of a separate system.

[0044] The controller 34 includes at least one processor 44 and a computer- readable storage device or media 46. The processor 44 can be any custom made or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), a co-processor of several processors associated with the controller 34, a semiconductor-based microprocessor (in the form of a microchip or chip set), a macroprocessor, any combination thereof, or generally any device that processes instructions. For example, the computer-readable storage device or media 46 can include volatile and nonvolatile storage in read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the processor 44 is powered off. The computer-readable storage device or media 46 can be implemented using any of a number of known memory devices, such as a PROM (programmable read-only memory), EPROM (erasable PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combination memory device capable of storing data, some of which represent executable instructions used by the controller 34 in controlling the vehicle 10.

[0045] The instructions can include one or more separate programs, each of which comprises an ordered listing of executable instructions for implementing logical functions. The instructions receive and process signals from the sensor system 28, execute logical, computational, and / or Figure 1 Although only one controller 34 is shown in the middle, embodiments of the vehicle 10 can include any number of controllers 34 that communicate over any suitable communication medium or combination of communication mediums and cooperate to process sensor signals, execute logic, computations, methods, and / or algorithms, and generate control signals to automatically control features of the vehicle 10. In various embodiments, the controller 34 is configured to implement an ADS.

[0046] Referring to Figure 2 , a functional block diagram of a controller 34 including a battery module thermal management system 100 is shown, in accordance with at least one embodiment. A battery system is used to power the vehicle 10. The battery system includes a plurality of battery modules 200. Each battery module 200 includes a plurality of battery cells. In at least one embodiment, the battery cells are lithium-ion battery cells. In alternative embodiments, the battery cells can be other types of battery cells. In at least one embodiment, the controller 34 is configured to manage a single battery module 200. In other words, a different controller 34 is dedicated to managing each individual battery module 200 in the battery system. In alternative embodiments, the controller 34 is a battery management system that is configured to manage all of the battery modules 200 in the battery system of the vehicle 10.

[0047] The controller 34 includes at least one processor 44 and at least one memory 46. The at least one processor 44 is a programmable device that includes one or more instructions stored in or associated with the at least one memory 46. The at least one memory 46 includes instructions that the at least one processor 44 is configured to execute. The at least one memory 46 includes embodiments of the battery module thermal management system 100. The controller 34 is configured to be communicatively coupled to the battery module 200, the propulsion system 20 of the vehicle 10, the braking system 26 of the vehicle 10, a vehicle event detection system 202 of the vehicle 10, and a vehicle display device 204 of the vehicle 10. The battery module 200 includes one or more battery module sensors 206, a compression control system 208, and a battery module state of charge (SOC) discharge system 210.

[0048] The controller 34 can include additional components that facilitate operation of the battery module thermal management system 100. Operation of the battery module thermal management system 100 will be described in greater detail below.

[0049] Referring Figure 3 , a flowchart representation of an exemplary method 300 of thermal management of a battery module 200 is shown, in accordance with at least one embodiment. The method 300 will be described with reference to an exemplary implementation of an embodiment of the battery module thermal management system 100. The vehicle 10 includes the battery module 200. The method 300 is implemented when the battery system of the vehicle 10, including the battery module 200, is in a charging process, parked, or in a driving condition. It will be appreciated in accordance with the present disclosure that the order of operations within the method 300 is not limited to being performed in the order shown in Figure 3 , but rather can be performed in one or more varied orders, as applicable and in accordance with the present disclosure.

[0050] At 302, the battery module thermal management system 100 receives battery module data from one or more battery module sensors 206. Examples of the battery module sensors 206 include, but are not limited to, a gas emission sensor, a module pressure sensor, and an acoustic emission sensor.

[0051] At 304, the battery module thermal management system 100 determines whether a battery cell anomaly has occurred in a battery cell of the battery module 200 based on the received battery module data. The battery cell anomaly can be a precursor to a thermal propagation condition in the battery module 200. Early detection of the battery cell anomaly in the battery module 200 enables the battery module thermal management system 100 to implement actions to mitigate and / or prevent the occurrence of a thermal propagation condition in the battery module 200, before the battery module 200 deteriorates to a thermal propagation condition.

[0052] An example of a battery cell anomaly is a short circuit. In the initial stages of a battery cell anomaly, the short circuit is a soft short circuit with a high resistance. Over time, the resistance gradually decreases, leading to a full short circuit, resulting in a thermal propagation condition within the battery module 200 containing the battery cell associated with the battery cell anomaly. In many instances, the battery cell deterioration can occur in the battery module 200 due to the presence of a foreign object in the battery cell. The foreign object can have been brought into the battery cell during the manufacturing process.

[0053] When a battery cell anomaly begins to occur in a battery cell of the battery module 200, the battery cell begins to emit flammable and / or hazardous gases. A gas emission sensor disposed within or in close proximity to the battery module 200 is configured to detect when such gases are emitted by a battery cell in the battery module 200. The emission of the gases typically results in an increase in pressure within the battery module 200. A module pressure sensor is configured to detect the increase in pressure within the battery module 200. Furthermore, when a battery cell anomaly occurs, the battery cell often emits a sound that can be detected by an acoustic emission sensor.

[0054] The battery module thermal management system 100 determines whether a battery cell anomaly has occurred in the battery cells of the battery module 200 based on whether the battery module data indicates the presence of gas, an increase in pressure within the battery module, and / or the generation of sound.

[0055] If the battery module thermal management system 100 determines that no battery cell anomaly has occurred in the battery cells of the battery module 200, the method 300 returns to 302. If the battery module thermal management system 100 determines that a battery cell anomaly has occurred in the battery cells of the battery module 200, the method 300 proceeds to 306.

[0056] At 306, the battery module thermal management system 100 generates a battery system anomaly notification for display on the vehicle display device 204 of the vehicle 10. In at least one embodiment, the battery module thermal management system 100 is configured to generate the battery system anomaly notification for transmission to a vehicle service center associated with the vehicle 10.

[0057] At 308, the battery module thermal management system 100 issues a command to the compression control system 208 of the battery module 200 to place the battery module 200 in an uncompressed position.

[0058] Reference Figure 4 is shown a functional block diagram representation of the battery module 200 including the compression control system 208, in accordance with at least one embodiment. The battery module 200 includes a plurality of battery cells 402. The battery cells 402 are lithium-ion battery cells. In at least one embodiment, the battery cells 402 are pouch battery cells 402. In at least one embodiment, the battery cells 402 are prismatic battery cells. In at least one embodiment, each of the plurality of battery cells 402 includes a first side having a planar surface and a second side having a planar surface. The second side of the battery cell 402 is opposite the first side of the battery cell 402.

[0059] The compression control system 208 includes a first compression plate 404 disposed at one end of the battery module 200 and a second compression plate 406 disposed at another end of the battery module 200. The plurality of battery cells 402 of the battery module 200 are disposed between the first compression plate 404 and the second compression plate 406. The first side and the second side of each battery cell 402 are parallel to the first compression plate 404 and the second compression plate 406. The battery cells 402 are arranged between the first compression plate 404 and the second compression plate 406 such that the planar surface of one battery cell 402 is proximate to the planar surface of an adjacent battery cell 402.

[0060] In at least one embodiment, a compression pad 408 is disposed between each compression plate 404, 406 and a battery cell 402 disposed adjacent to the compression plate 404, 406. The compression control system 208 includes a compression mechanism. In at least one embodiment, the compression mechanism includes four fastening rods 410, four springs 412, and four solenoids 414. Each fastening rod 410 has one end coupled to the first compression plate 404 and another end coupled to the second compression plate 406 via a spring 412. The solenoid 414 is coupled to each spring 412.

[0061] The compression mechanism has a default compression position. When the compression mechanism is in the default compression position, the battery cells 402 are compressed between the first compression plate 404 and the second compression plate 406. The first compression plate 404 and the second compression plate 406 are held in a first spaced apart position by the compression mechanism in the default compression position. In the default compression position, the springs 412 are held in a compressed state. Upon activation of the solenoid 414, the springs 412 are released from the compressed state to an uncompressed state, thereby moving the first compression plate 404 and the second compression plate 406 from the first spaced apart position to a second spaced apart position. The second spaced apart position is greater than the first spaced apart position. The solenoid 414 is activated in response to a command to place the battery module 200 in the uncompressed position.

[0062] When the battery module thermal management system 100 issues a command to the compression control system 208 of the battery module 200 to place the battery module 200 in the uncompressed position at 308, the compression mechanism places the battery module 200 in the uncompressed position by increasing the distance between the first compression plate 404 and the second compression plate 406 to the second spaced apart position. Placing the battery module 200 in the uncompressed position increases the space between adjacent battery cells 402 in the battery module 200.

[0063] An uncompressed battery cell 402 generally has more resistance to external heating than a compressed battery cell 402. An uncompressed battery cell 402 can require a longer heating period and a higher temperature to trigger a thermal propagation condition of the battery module 200 than a compressed battery cell 402. The internal delamination of the layers during heating can act to prevent internal short circuits from occurring within the battery module 200 without compression, thereby preventing and / or mitigating a thermal propagation event. The decompression of the battery cells 402 within the battery module 200 increases the cell-to-cell contact resistance and can create an air gap between adjacent battery cells 402 within the battery module 200.

[0064] In at least one embodiment, the battery module 200 includes a cooling plate 416. When the battery module thermal management system 100 determines that a battery cell anomaly has occurred in the battery cells 402 of the battery module 200, the battery module thermal management system 100 coordinates an increase in coolant flow to the cooling plate 416.

[0065] In at least one embodiment, the battery cells 402 in the battery module 200 are coated with an intumescent coating. Intumescent coatings are fireproof coatings. When the battery module 200 is placed in an uncompressed position, the intumescent coating is provided with space to expand when exposed to heat and provide an insulating film around the battery cells 402, mitigating heat propagation conditions within the battery module 200.

[0066] In at least one embodiment, the battery module 200 is immersed in a coolant to achieve immersion cooling. When the battery module 200 is placed in an uncompressed position, the coolant flows between the battery cells 402 in the battery module 200, mitigating heat propagation conditions within the battery module 200.

[0067] Referring again to Figure 3 At 310, the battery module thermal management system 100 determines whether the state of charge (SOC) of the battery module 200 is below an SOC threshold. The SOC threshold defines a SOC level of the battery cells in the battery module 200 that can prevent heat propagation from occurring within the battery module 200 or can prevent cell-to-cell propagation in the event that heat propagation has already begun in a battery cell experiencing a battery cell anomaly. In at least one embodiment, the SOC threshold is determined based on the chemistry and / or configuration of the battery cells in the battery module 200.

[0068] If the battery module thermal management system 100 determines that the state of charge (SOC) of the battery module 200 is not below the SOC threshold, at 312, the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 to lower the SOC of the battery module 200 below the SOC threshold. Lowering the SOC of the battery module 200 below the SOC threshold when a battery cell anomaly is detected in the battery module 200 can lower the battery cell SOC to a safer level, which can prevent heat propagation from occurring within the battery module 200 or can prevent cell-to-cell propagation in the event that heat propagation has already begun in a battery cell experiencing a battery cell anomaly.

[0069] In at least one embodiment, the battery module thermal management system 100 simultaneously issues a command to the compression control system 208 to decompress the battery module 200 and issues a command to the battery module SOC discharge system 210 to lower the SOC of the battery module 200 below the SOC threshold, such that placing the battery module 200 in the uncompressed position occurs in parallel with lowering the SOC of the battery module 200.

[0070] In at least one embodiment, the battery module thermal management system 100 determines whether the battery system of the vehicle 10 including the battery module 200 is coupled to a grid charging system. If the battery module thermal management system 100 determines that the battery system of the vehicle 10 including the battery module 200 is coupled to a grid charging system, the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 to lower the SOC of the battery module 200 by supplying energy from the battery module 200 back to the grid charging system. Energy in the battery module 200 is dissipated via the grid charging system, thereby lowering the SOC of the battery module 200. In at least one embodiment, the battery module SOC discharge system 210 coordinates dissipation of energy in the battery module 200 back to the grid charging system until the SOC of the battery module 200 falls below the SOC threshold.

[0071] In at least one embodiment, the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 to lower the SOC of the battery module 200 by supplying energy to one or more vehicle accessories of the vehicle 10 and supplying energy from the battery module 200 to the one or more vehicle accessories. An example of a vehicle accessory is an air conditioning system of the vehicle 10. In at least one embodiment, the battery module SOC discharge system 210 coordinates dissipation of energy in the battery module 200 by supplying energy to the one or more vehicle accessories until the SOC of the battery module 200 falls below the SOC threshold.

[0072] In at least one embodiment, the battery module thermal management system 100 determines whether the vehicle 10 including the battery module 200 is parked. If the battery module thermal management system 100 determines that the vehicle 10 including the battery module 200 is parked, the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 to lower the SOC of the battery module 200 by supplying energy to the propulsion system 20 of the vehicle 10, activating the braking system 26 of the vehicle 10, and supplying energy from the battery module 200 to the propulsion system 20 and the braking system 26. In at least one embodiment, the battery module SOC discharge system 210 coordinates dissipation of energy in the battery module 200 by supplying energy from the battery module 200 to the propulsion system 20 and the braking system 26 until the SOC of the battery module 200 falls below the SOC threshold.

[0073] In at least one embodiment, the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 to reduce the SOC of the battery module 200 by dissipating energy from the battery module 200 via the dedicated integrated resistor 502. Referring to Figure 5 , a functional block diagram representation of a battery system 500 including a dedicated integrated resistor 502 is shown, in accordance with at least one embodiment. The battery system 500 includes a plurality of battery modules 200. Each battery module 200 is coupled to a bypass switch 504. Under normal operating conditions, the bypass switch 504 and the resistor switch 506 remain in an open position. When the battery module thermal management system 100 detects a battery cell anomaly in one of the battery modules 200, that battery module 200 is identified as a failed battery module 200. The battery module thermal management system 100 coordinates closing the bypass switch 504 for the healthy battery modules 200, closing the resistor switch 506, and leaving the bypass switch 504 for the failed battery module 200 in an open position, thereby enabling dissipation of energy from the failed battery module 200 via the dedicated integrated resistor 502. In at least one embodiment, the dedicated integrated resistor 502 is disposed on a cooling plate with the resistor switch 506.

[0074] Referring again to Figure 3 , when at 312 the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 to reduce the SOC of the battery module 200 below the SOC threshold, one or more of the above-described methods of reducing the SOC of the battery module 200 below the SOC threshold can be used in combination to reduce the SOC of the battery module 200. At 314, the battery module thermal management system 100 generates a vehicle service notification for display on the vehicle display device 204.

[0075] If at 310 the battery module thermal management system 100 determines that the state of charge (SOC) of the battery module 200 is below the SOC threshold, the method 300 proceeds to 314. At 314, the battery module thermal management system 100 generates a vehicle service notification for display on the vehicle display device 204.

[0076] Referring to Figure 6 , a flowchart representation of an exemplary method 600 of thermal management of a battery module 200 in response to a vehicle event is shown, in accordance with at least one embodiment. The method 600 will be described with reference to an exemplary implementation of an embodiment of the battery module thermal management system 100 of the vehicle 10. The vehicle 10 includes a battery system. The battery system includes a plurality of battery modules 200. As can be appreciated in light of this disclosure, the order of operations within the method 600 is not limited to being performed in the order shown in Figure 6 , but rather can be performed in one or more varied orders, as applicable and in accordance with this disclosure.

[0077] At 602, the battery module thermal management system 100 receives a vehicle event notification from the vehicle event detection system 202. In at least one embodiment, the vehicle event detection system 202 is configured to determine whether a vehicle event has occurred based on sensor data received from the sensor system 28 of the vehicle 10. If the vehicle event detection system 202 determines that a vehicle event has occurred, the vehicle event detection system 202 is configured to generate a vehicle event notification. The vehicle event detection system 202 is configured to transmit the generated vehicle event notification to the battery module thermal management system 100. The vehicle event can include contact between the vehicle 10 and another vehicle or contact between the vehicle 10 and an object that can result in damage to the vehicle battery system and increase the risk of a potential battery module thermal propagation situation.

[0078] At 604, the battery module thermal management system 100 issues a command to the compression control system 208 of each battery module 200 in the battery system of the vehicle 10 to place the battery module 200 in an uncompressed position. At 606, the battery module thermal management system 100 issues a command to the battery module SOC discharge system 210 of each battery module 200 in the battery system of the vehicle 10 to reduce the SOC of the battery module 200 by dissipating energy from the battery module 200. One or more of the methods of dissipating energy from the battery module 200 described above can be used. In at least one embodiment, the battery module thermal management system 100 issues the command to the compression control system 208 of each battery module 200 in parallel with the command to the battery module SOC discharge system 210 of each battery module 200, such that the battery module 200 is placed in an uncompressed state in parallel with the dissipation of energy from the battery module 200. At 608, the battery module thermal management system 100 generates a handle with care vehicle notification for display on the vehicle display device 204.

[0079] While at least one example embodiment has been presented in the foregoing detailed description, it should be appreciated that a large number of modifications can be made. It should also be appreciated that the example embodiment or embodiments are only examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an example embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of this disclosure as set forth in the appended claims and the legal equivalents thereof.

Claims

1. A battery module thermal management system, comprising: processor; as well as A memory, communicatively coupled to the processor, includes instructions that, when executed by the processor, cause the processor to: Battery module data associated with a first battery module is received from at least one battery module sensor, the first battery module comprising a plurality of battery cells; Based on the battery module data, determine whether a battery cell abnormality has occurred in at least one battery cell of the first battery module; as well as Based on the determination, a first command is issued to the compression control system to place the first battery module in an uncompressed position, wherein the compression control system includes: A first compression plate is disposed at the first end of the first battery module; A second compression plate is disposed at the second end of the first battery module, wherein the second end of the first battery module is opposite to the first end of the first battery module, and the plurality of battery cells are disposed between the first compression plate and the second compression plate; and A compression mechanism is coupled to the first compression plate and the second compression plate, the compression mechanism having a default compressed position for holding the first compression plate and the second compression plate at a first spaced-apart position and an uncompressed position for placing the first compression plate and the second compression plate at a second spaced-apart position in response to the first command, the first spaced-apart position being smaller than the second spaced-apart position.

2. The system according to claim 1, wherein, The compression mechanism includes: At least one fastening rod has a first end coupled to the first compression plate and a second end coupled to the second compression plate via a spring; and A solenoid coupled to the spring, wherein, when the solenoid is activated, the spring is released from a compressed state to an uncompressed state, thereby moving the first compression plate and the second compression plate from the first spaced-apart position to the second spaced-apart position.

3. The system according to claim 1, wherein, The memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell malfunction has occurred in at least one battery cell of the first battery module: Determine whether the state of charge (SOC) of the first battery module is greater than the SOC threshold; as well as Based on the determination, a second command is issued to the battery module SOC discharge system to reduce the SOC of the first battery module below the SOC threshold.

4. The system according to claim 3, wherein, The memory includes further instructions that, when executed by the processor, cause the processor to: Determine whether the vehicle, including the first battery module, is coupled to the grid charging system; and The second command is issued to the battery module's SOC discharge system to reduce the SOC of the first battery module by supplying energy back to the grid charging system from the first battery module.

5. The system according to claim 3, wherein, The memory includes further instructions that, when executed by the processor, cause the processor to issue a second command to the battery module SOC discharge system to reduce the SOC of the first battery module by activating the operation of a vehicle accessory of the vehicle including the first battery module and supplying energy from the first battery module to the vehicle accessory.

6. The system according to claim 3, wherein, The memory includes further instructions that, when executed by the processor, cause the processor to: Determine whether the vehicle, including the first battery module, is parked; and The second command is issued to the battery module's SOC discharge system to reduce the SOC of the first battery module by activating the operation of the vehicle's propulsion and braking systems and supplying energy from the first battery module to the propulsion and braking systems.

7. The system according to claim 3, wherein, The memory includes further instructions that, when executed by the processor, cause the processor to, upon determining that a battery cell malfunction has occurred in at least one battery cell of the first battery module: The second command is issued to the battery module's SOC discharge system to reduce the SOC of the first battery module by dissipating energy from the first battery module via a dedicated integrated resistor.

8. The system according to claim 1, wherein, Each of the plurality of battery cells is coated with an intumescent coating.

9. The system according to claim 1, wherein: The vehicle includes multiple battery modules, including the first battery module; Each of the plurality of battery modules includes an associated compression control system and an associated battery module SOC discharge system; and The memory includes further instructions that, when executed by the processor, cause the processor to: Receive vehicle event notifications associated with the vehicle; A third command is issued to the compression control system of each of the plurality of battery modules to place the battery module in an uncompressed position; as well as A fourth command is issued to the SOC discharge system of each of the plurality of battery modules to reduce the SOC of the battery module.

10. A thermal management method for a battery module, comprising: Battery module data associated with a first battery module is received from at least one battery module sensor, the first battery module comprising a plurality of battery cells; Based on the battery module data, determine whether a battery cell abnormality has occurred in at least one battery cell of the first battery module; as well as Based on the determination, a first command is issued to the compression control system to place the first battery module in an uncompressed position, wherein the compression control system includes: A first compression plate is disposed at the first end of the first battery module; A second compression plate is disposed at the second end of the first battery module, wherein the second end of the first battery module is opposite to the first end of the first battery module, and the plurality of battery cells are disposed between the first compression plate and the second compression plate; and A compression mechanism is coupled to the first compression plate and the second compression plate, the compression mechanism having a default compressed position for holding the first compression plate and the second compression plate at a first spaced-apart position and an uncompressed position for placing the first compression plate and the second compression plate at a second spaced-apart position in response to the first command, the first spaced-apart position being smaller than the second spaced-apart position.

Images