Design and Method of Rechargeable Energy Storage System Cover with Inlet and Sealing Plug

Abstract

A rechargeable energy storage system (RESS) component includes a battery module, a housing, potting material, and a plug. The housing houses the battery module within a cavity. The housing includes a shell portion and a cap engaged with the shell portion to define the cavity. The cap is above and extends along at least a portion of the cavity. The cap includes a cap body and a port extending through the cap body and is configured to fluidly connect the cavity and the exterior of the housing. Potting material is injected into the cavity through the port. The potting material flows within the cavity and between the cap and the battery module. A plug is disposed within the port of the cap and hermetically seals the cavity to the exterior of the housing.

Description

Technical Field

[0001] This disclosure generally relates to a rechargeable energy storage system (RESS) for a vehicle. Background Technology

[0002] The information provided in this section is for the purpose of presenting the general context of this disclosure. The work of the currently named inventors, to the extent described in this section, and in respect of aspects that may not otherwise qualify as prior art at the time of filing, is neither expressly nor implicitly acknowledged as prior art to this disclosure.

[0003] Assembling the RESS before installation on the vehicle can be tedious and cumbersome. In many cases, the battery module is housed within a package or enclosure of the RESS, which typically consists of a lower section and an upper section or cover that join together to house the battery module. Sealing and securing the battery module within the enclosure is crucial for the proper operation of the RESS. For example, sealing the battery module within the RESS enclosure prevents gases or other materials from escaping through unintended paths. Furthermore, securing the battery module within the enclosure protects it from movement during vehicle operation. Typically, expanding foam is placed within the enclosure to fill the gaps between the battery modules and essentially fill the enclosure.

[0004] Before the upper portion of the enclosure is installed and sealed to the lower portion, expansion foam is typically placed within the enclosure to ensure it is positioned within all necessary gaps. However, in doing so, the expansion foam can expand at the edges of the lower portion of the enclosure, especially if the installation of the upper portion is delayed. Expansion foam located at or above the edges can prevent the upper portion of the enclosure from fully and completely sealing to the lower portion, thus preventing the battery module from being completely sealed within the enclosure. In other words, gaps, cavities, or leaks can form between the lower and upper portions of the enclosure, preventing a complete seal and thus preventing the enclosure from being airtight and watertight. Gaps, cavities, and leaks can also form if the upper portion of the enclosure is not properly aligned relative to the lower portion. Due to the size and construction of the upper and lower portions of the enclosure, and the limited time available to install the upper portion of the enclosure onto the lower portion before the expanding foam seeps out of the edge of the lower portion, properly aligning the upper portion relative to the lower portion can be challenging. Furthermore, significant time may be required during installation to firmly press and hold the upper portion against and hold it to the lower portion. The cumbersome and laborious process of sealing the battery module within the enclosure carries numerous risks of eventual failure. Summary of the Invention

[0005] One aspect of this disclosure provides a rechargeable energy storage system (RESS) assembly. The RESS assembly includes a battery module, a housing, potting material, and a plug. The housing houses the battery module within a cavity. The housing includes a shell portion and a cover engaged with the shell portion to define the cavity. The cover is over at least a portion of the cavity and extends along at least a portion of the cavity. The cover includes a cover body and a port extending through the cover body and configured to fluidly connect the cavity and an exterior of the housing. Potting material is injected into the cavity through the port. The potting material flows within the cavity and between the cover and the battery module. A plug is disposed within the port of the cover and hermetically seals the cavity to the exterior of the housing.

[0006] Embodiments of this aspect of the present disclosure may include one or more of the following optional features. In some examples, the cap includes an outer plate, an inner plate, and a core disposed between the outer and inner plates. In some further examples, the outer and inner plates are made of metallic materials, and the core is made of a composite material. In some even further examples, the plug is made of a composite material and is configured to hermetically seal the port of the cap via friction welding between the plug and the composite material of the core of the cap. In some still further examples, the plug is made of metallic material and is configured to hermetically seal the port of the cap via friction welding between the plug and the metallic material of at least one of the outer and inner plates. In some other even further examples, the inner plate of the cap includes a flow channel extending from the port for guiding the flow of potting material in the injection cavity.

[0007] In some embodiments, the cap body comprises a metallic material. In some further embodiments, the plug comprises a metallic material and is configured to hermetically seal the port of the cap via a mechanical fastening between the plug and the metallic material of the cap.

[0008] In some configurations, the ports include multiple ports extending through the cover at discrete locations, and the plugs include multiple plugs, each of the multiple plugs being disposed within a corresponding port of the multiple ports to hermetically seal the cavity.

[0009] In some examples, the cover is welded to the shell.

[0010] Another aspect of this disclosure provides a vehicle. The vehicle includes a rechargeable energy storage system (RESS) assembly. The RESS assembly includes a battery module, a housing, potting material, and a plug. The housing houses the battery module within a cavity. The housing includes a shell portion and a cover engaged with the shell portion to define the cavity. The cover is over at least a portion of the cavity and extends along at least a portion of the cavity. The cover includes a cover body and a port extending through the cover body and is configured to fluidly connect the cavity and the exterior of the housing. Potting material is injected into the cavity through the port. The potting material flows within the cavity and between the cover and the battery module. A plug is disposed within the port of the cover and hermetically seals the cavity to the exterior of the housing.

[0011] Embodiments of this aspect of the present disclosure may include one or more of the following optional features. In some examples, the cover includes an outer plate, an inner plate, and a core disposed between the outer and inner plates. In some further examples, the outer and inner plates are made of metallic material, and the core is made of composite material. In some even further examples, the plug is made of composite material and is configured to hermetically seal the port of the cover via friction welding between the plug and the composite material of the core of the cover.

[0012] In some embodiments, the cap and plug are made of metallic material, and the plug is configured to hermetically seal the port of the cap via a mechanical fastening between the plug and the cap.

[0013] Another aspect of this disclosure provides a method for manufacturing a rechargeable energy storage system (RESS) component. The method includes: (i) disposing a battery module within a cavity of a housing, the housing including a cover and a shell portion; (ii) engaging the cover of the housing to the shell portion of the housing to accommodate the battery module within the cavity of the housing, the cover over and extending along at least a portion of the cavity, and including a cover body and a port extending through the cover body and fluidly connecting the cavity to an exterior of the housing; (iii) injecting a potting material into the cavity via the port of the cover body, the potting material flowing within the cavity and between the cover and the battery module; and (iv) disposing a plug within the port of the cover body to hermetically seal the cavity to an exterior of the housing.

[0014] Embodiments of this aspect of the present disclosure may include one or more of the following optional features. In some examples, the cover includes an outer plate, an inner plate, and a core disposed between the outer and inner plates. In some further examples, the outer and inner plates are made of metallic materials, and the core is made of a composite material. In some even further examples, the plug is made of a composite material, and the plug hermetically seals the port of the cover via friction welding between the plug and the composite material of the core of the cover.

[0015] In some embodiments, the cap and plug are made of metallic material, and the plug hermetically seals the port of the cap via a mechanical fastening between the plug and the cap. Attached Figure Description

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

[0017] Figure 1 This is a perspective view of a vehicle including a rechargeable energy storage system (RESS) component according to this disclosure;

[0018] Figure 2A yes Figure 1 A perspective view of the RESS component, with the cover removed from the shell of the RESS component;

[0019] Figure 2B yes Figure 2A A perspective view of the RESS assembly, in which the cover is welded to the housing and encloses the battery module within the cavity of the RESS assembly;

[0020] Figure 3 yes Figure 2A Top view of the cover of the RESS component;

[0021] Figure 4 yes Figure 2B A cross-sectional view of the RESS component, which includes a filling syringe positioned at the port of the cap;

[0022] Figure 5 yes Figure 2B A cross-sectional view of a RESS assembly, which includes a plug disposed within a port of the cap and potting material disposed within a cavity;

[0023] Figure 6 This is a flowchart of an example method for assembling RESS components;

[0024] Figure 7 It is a cross-sectional view of another RESS component according to this disclosure, and includes a filling syringe positioned at the port of the cap of the RESS component; and

[0025] Figure 8 yes Figure 7 A cross-sectional view of a RESS assembly, which includes a plug disposed within a port of the cap and potting material disposed within a cavity of the RESS assembly.

[0026] Throughout the accompanying drawings, corresponding reference numerals indicate the relevant parts. Detailed Implementation

[0027] The example configuration will now be described more fully with reference to the accompanying drawings. The example configuration is provided so that this disclosure will be thorough and will fully communicate the scope of this disclosure to those skilled in the art. Specific details, such as examples of specific components, apparatus, and methods, are set forth to provide a thorough understanding of the configuration of this disclosure. It will be apparent to those skilled in the art that the specific details are not required, the example configuration can be implemented in many different forms, and the specific details and example configuration should not be construed as limiting the scope of this disclosure.

[0028] The terminology used herein is for the purpose of describing a particular exemplary configuration only and is not intended to be restrictive. As used herein, the singular articles “a” and “the” may be intended to include plural forms as well, unless the context clearly indicates otherwise. The terms “comprising,” “containing,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Unless specifically identified as an order of execution, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown. Additional or alternative steps may be employed.

[0029] When an element or layer is referred to as being “on,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly on, joined to, connected to, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as being “directly on,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0030] The terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply order or sequence. Therefore, without departing from the teachings of the example configuration, the first element, component, region, layer, or section discussed below may be referred to as the second element, component, region, layer, or section.

[0031] In this application, including the following definitions, the term "module" may be replaced by the term "circuit". The term "module" may refer to, be part of, or include: application-specific integrated circuits (ASICs); digital, analog, or mixed-signal analog / digital discrete circuits; digital, analog, or mixed-signal analog / digital integrated circuits; combinational logic circuits; field-programmable gate arrays (FPGAs); processors (shared, dedicated, or grouped) that execute code; memory (shared, dedicated, or grouped) that stores code executed by the processor; other suitable hardware components that provide the described functionality; or combinations of some or all of the foregoing, such as in a system-on-a-chip.

[0032] The term "code" as used above can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. The term "shared processor" covers a single processor that executes some or all of the code from multiple modules. The term "group processor" covers a processor that, in combination with additional processors, executes some or all of the code from one or more modules. The term "shared memory" covers a single memory that stores some or all of the code from multiple modules. The term "group memory" covers memory that, in combination with additional memory, stores some or all of the code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium." The term "computer-readable medium" does not include transient electrical and electromagnetic signals propagating through a medium, and therefore can be considered tangible and non-transitory memory. Non-limiting examples of non-transitory memory include tangible computer-readable media, which include non-volatile memory, magnetic memory, and optical memory.

[0033] The apparatus and methods described in this application can be implemented, in part or in whole, by one or more computer programs executed by one or more processors. The computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. The computer program may also include and / or depend on stored data.

[0034] A software application (i.e., a software resource) can refer to computer software that enables a computing device to perform tasks. In some examples, a software application may be referred to as an "application," "app," or "program." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and game applications.

[0035] Non-transitory memory can be a physical device used to temporarily or permanently store programs (e.g., instruction sequences) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used in firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase-change memory (PCM), and magnetic disks or magnetic tapes.

[0036] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and can be implemented using high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., disk, optical disk, memory, programmable logic device (PLD)) used to provide machine instructions and / or data to a programmable processor, including machine-readable media that receive machine instructions as machine-readable signals. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0037] Various implementations of the systems and techniques described herein can be implemented in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (Application-Specific Integrated Circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can include implementations in one or more computer programs executable and / or interpretable on a programmable system, which includes at least one programmable processor, which may be dedicated or general-purpose, coupled to receive data and instructions from a storage system, at least one input device, and at least one output device, and to transmit data and instructions to the storage system, at least one input device, and at least one output device.

[0038] The processes and logic described in this specification can be executed by one or more programmable processors (also known as data processing hardware) that execute one or more computer programs to perform functions by manipulating input data and generating output. The processes and logic can also be executed by special-purpose logic circuitry, such as FPGAs (Field-Programmable Gate Arrays) or ASICs (Application-Specific Integrated Circuits). Processors suitable for executing computer programs include, for example, both general-purpose microprocessors and special-purpose microprocessors, as well as any one or more processors of any kind of digital computer. Typically, the processor receives instructions and data from read-only memory or random access memory, or both. The basic elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more mass storage devices (e.g., magnetic disks, magneto-optical disks, or optical disks) for storing data, or operatively coupled to receive data from or transfer data to one or more mass storage devices, or both. However, a computer does not need to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including, for example, semiconductor memory devices such as EPROM, EEPROM, and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. Processors and memory may be supplemented by or incorporated into dedicated logic circuitry.

[0039] To provide interaction with a user, one or more aspects of this disclosure can be implemented on a computer having a display device for displaying information to the user, such as a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touchscreen, and optionally a keyboard and pointing device, such as a mouse or trackball, through which the user can provide input to the computer. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, voice, or tactile input. Furthermore, the computer can interact with the user by sending documents to and receiving documents from the device used by the user; for example, by sending a webpage to a web browser on the user's client device in response to a request received from a web browser.

[0040] refer to Figures 1 to 5Vehicle 10 (such as an electric vehicle (EV), plug-in hybrid electric vehicle (PHEV), or hybrid vehicle) includes a rechargeable energy storage system (RESS) component 100 configured to store, recharge, and supply power to components included in vehicle 10. For example, RESS component 100 may include a lithium-ion battery pack. RESS component 100 may at least partially power the propulsion system of vehicle 10. In this respect, when installed in vehicle 10, the energy stored in RESS component 100 can enable the propulsion system to drive or power vehicle 10.

[0041] RESS assembly 100 includes a housing, enclosure, or cover 102 for mounting RESS assembly 100 at vehicle 10 and protecting the electronic components of RESS assembly 100. Figure 2A and Figure 2B The housing 102 includes a lower portion or shell portion 104 and an upper portion or cover 106, wherein the cover 106 is welded and sealed to the shell portion 104 to define a cavity 108 within the housing 102. For example, a peripheral region 110 of the shell portion 104 may be welded and sealed to a peripheral region 112 of the cover 106, thereby forming an airtight and watertight seal between the shell portion 104 and the cover 106. The cover 106 may be joined to the shell portion 104 in any suitable manner, such as via an adhesive material disposed between the peripheral region 110 of the shell portion 104 and the peripheral region 112 of the cover, via mechanical fasteners (e.g., bolts, rivets, etc.).

[0042] One or more battery modules 114 are disposed within the cavity 108 of the housing 102. In this regard, a cover 106 extends over and along at least a portion of the battery modules 114 and the cavity 108. Both the housing 104 and the cover 106 comprise a rigid material, such as a metallic material (e.g., steel), a composite material (e.g., fiber-reinforced resin), or a combination of metallic and composite materials, to prevent deformation of the housing 102 and collapse of the cavity 108. For example, when the RESS assembly 100 is fully assembled and installed in the vehicle 10, the cavity 108 may be vacuum-sealed, thus creating a risk of collapse of the cavity 108 due to the pressure difference between the cavity 108 and the outside of the housing 102. In another example, the housing 102 may experience vibration, turbulence, or other minor movements during operation of the vehicle 10, such as when the vehicle 10 is traveling along a rough or uneven road, thus creating a risk of deformation of the housing 102. Furthermore, the housing 104 and cover 106 protect the battery module 114 and other electronic components of the RESS assembly 100 during vehicle collisions and other impacts. The housing 102 is kept rigid while the cover 106 maintains a seal against the housing 104.

[0043] Cover 106 includes cover body 116 and channel or port 118, cover body 116 forming a substantially planar plate above cavity 108 of housing 102, channel or port 118 extending through cover body 116 and configured to fluidly connect cavity 108 and the exterior of housing 102 when not covered or sealed. Figure 3 and Figure 4 In other words, once the cover 106 is sealed to the housing 104, the port 118 provides an entrance to the cavity 108. Furthermore, the port 118 provides access to the battery module 114 disposed in the cavity 108. The cover 106 may include any suitable number of ports 118, depending on the configuration of the RESS component 100, and as discussed further below. The configuration of the RESS component 100 may vary based on the vehicle 10 in which the RESS component 100 is installed. In the example shown, the ports 118 include six ports 118 extending through the cover 116 and arranged at discrete locations on the cover 106. However, it should be understood that, without departing from the context of this disclosure, the ports 118 may include fewer or more ports 118.

[0044] The cover 116 may comprise a variety of materials while maintaining rigidity. For example, the cover 116 may comprise an outer skin or outer panel 120 and an inner skin or inner panel 122 opposite to the outer panel 120. The outer panel 120 faces the exterior of the housing 102, while the inner panel 122 faces the cavity 108. Both the outer panel 120 and the inner panel 122 comprise metallic materials, such as steel, aluminum, or the like. The metallic materials of the outer panel 120 and the inner panel 122 provide structural durability, strength, and rigidity to the cover 106. The cover 116 may also include a core 124 disposed between the outer panel 120 and the inner panel 122. The core 124 comprises a composite material and may be completely surrounded by the outer panel 120 and the inner panel 122. The composite material of the core 124 provides the cover 106 with increased strength, weight reduction, and noise reduction. Furthermore, the composite material of the core 124 can provide thermal insulation to the cavity 108 of the RESS assembly 100.

[0045] RESS assembly 100 also includes potting material 126, which is injected through one or more ports 118 to substantially fill the cavity and gap between the battery module 114 and the cover 106 within the cavity 108. Figure 4 and Figure 5The potting material 126 may be an expandable foam, a thermosetting chemical foam, or the like. In this respect, the potting material 126 is configured to expand upon curing and hardening. In other words, the potting material 126 solidifies from a flowing liquid to a hardened solid over a period of time. The potting material 126 is disposed within a cavity 108 between the cap 106 and the battery module 114, and solidifies within the cavity 108. Furthermore, as the potting material 126 flows within the cavity 108 (before curing), the potting material 126 can surround and encapsulate the battery module 114, thereby further securing and insulating the battery module 114 within the housing 102. The potting material 126 is configured to be injected into the cavity 108 via a potting injector 200 through port 118 of the cap 106, details of which will be described in more detail below.

[0046] Therefore, the location of the corresponding port 118 at the cap 106 can correspond to gaps and spaces as well as other desired locations of the potting material 126 within the cavity 108. For example, the ports 118 can be arranged on the cap 106 in a substantially uniform manner (i.e., with substantially equal spacing between adjacent ports 118) to provide uniform or equal filling of the potting material 126 upon injection through the ports 118. Alternatively, the ports 118 can be arranged at or near portions of the RESS assembly 100 that are known to have a large volume of empty space within the cavity 108, such as at or near the periphery of the RESS assembly 100, at a smaller portion of the battery module 114, or at or near portions lacking battery components. During the injection of the potting material 126, a vacuum source can be connected to the cavity 108 of the RESS assembly 100 (such as at one of the ports 118) to cause the potting material 126 to flow within the cavity 108 and substantially fill the volume of the RESS assembly 100.

[0047] To facilitate the flow of the potting material 126 within the cavity 108, the inner plate 122 of the cap 116 may include one or more flow channels 128 extending at or near the port 118. Figure 3-5In other words, the flow channel 128 extends from the port 118 along the inner plate 122 and can guide the flow of the potting material 126 injected into the cavity 108 to better guide and diffuse the flow of the potting material 126. Based on the configuration of the flow channel 128, guiding the flow of the potting material 126 allows the potting material 126 to be intentionally directed to certain areas of the cavity 108 or certain areas of the battery module 114. For example, the flow channel 128 may be recessed into the inner plate 122 in an "H" shape, as seen in the illustrated example. The "H" shape allows the potting material 126 to flow along, within, or relative to the "H" shape, thus guiding it to a specific area within the cavity 108 before curing begins. It should be understood that the shape and configuration of the flow channel 128 can vary without departing from the context of this disclosure. Furthermore, multiple ports 118 may correspond to multiple flow channels 128, including each port 118 at the cover 106 corresponding to each of the flow channels 128 at the inner plate 122. Furthermore, the inner plate 122 of the cover 106 may include flow channels 128 with different corresponding shapes. For example, the flow channels 128 at or near the central portion of the cover 106 may include generally symmetrical shapes, such as “H” or “X” shapes, to uniformly distribute the potting material 126 from the central portion of the cavity 108, while the flow channels 128 at the edge portions of the cover 106 may include other shapes, such as “T” shapes, which are configured to guide the potting material 126 toward the central portion of the cavity 108 and / or along the edge portions of the cavity 108.

[0048] RESS assembly 100 also includes a plug 130, which is used to seal RESS assembly 100 when potting material 126 is injected into cavity 108. Figure 5 The plug 130 is then positioned within port 118 of cap 106. The plug 130 can be a mechanically thermo-fastener, such as a rivet, a thermo-adhesive-bonded boss, or the like. In one example, the plug 130 may comprise a composite material configured to hermetically seal port 118 of cap 106 via friction welding between the plug 130 and the composite material of core 124 of cap 116. That is, after potting material 126 is injected into cavity 108 through port 118, the composite plug 130 can be inserted into port 118 and joined to composite core 124 of cap 106 via friction welding.

[0049] In another example, the plug 130 may comprise a metallic material configured to hermetically seal the port 118 of the cap 106 via friction welding between the plug 130 and at least one of the outer plate 120 and inner plate 122 of the cap 116. In other words, the metal plug 130 can be inserted into the port 118 and joined to at least one of the outer metal plate 120 and inner metal plate 122 via friction welding. The metal plug 130 may be further welded to the outer plate 120 after friction welding.

[0050] Furthermore, the plugs 130 may include a plurality of plugs 130 corresponding to a plurality of ports 118 at the cap 106. In other words, the number of plugs 130 at the RESS assembly 100 corresponds to the number of ports 118 at the RESS assembly 100. Additionally, some plugs 130 may include composite plugs, while others may include metal plugs. In this respect, each of the plugs 130 is securely disposed at its corresponding port 118, thereby providing a hermetically sealed seal between the cavity 108 and the exterior of the housing 102. During the manufacture of the RESS assembly 100, the plugs 130 are positioned at the ports 118 after the potting material 126 has been injected into the cavity 108.

[0051] Continue to refer to Figure 1-5 And refer to Figure 6 An example method 300 for manufacturing and assembling the RESS assembly 100 includes, at operation 302, providing a housing 104, a cover 106, and one or more battery modules 114. At operation 302, method 300 includes disposing one or more battery modules 114 within the housing 104. At operation 304, the method includes attaching the cover 106 to the housing 104, for example, via welding, to form a housing 102. For example, a peripheral region 110 of the housing 104 may be welded and sealed to a peripheral region 112 of the cover 106, thereby forming an airtight and watertight seal between the housing 104 and the cover 106. The battery modules 114 are housed within a cavity 108 of the housing 102, between the housing 104 and the cover 106, and the seal from the cover 106 to the housing 104 encloses the battery modules 114 within the cavity 108 of the housing 102. It should be understood that the battery modules 114 may be enclosed within a portion of the cavity 108. The empty space or gap of cavity 108 can extend within housing 102 between battery module 114 and cover 106.

[0052] After sealing the cover 106 to the housing 104 with the battery module 114 disposed within the cavity 108, method 300 includes, at operation 306, injecting potting material 126 into the cavity 108 via a potting injector 200 through port 118. When the potting material 126 is initially injected into the cavity 108, the potting material 126 is in a liquid state, thereby allowing the potting material 126 to flow freely within the cavity 108 and encapsulate the battery module 114. Furthermore, a flow channel 128, including at the inner plate 122 of the cover 116 and extending from port 118, facilitates the guidance of the flow of the potting material 126 throughout the cavity 108. The shape and orientation of the flow channel 128 can be configured as needed. Moreover, the shape, orientation, and configuration of the flow channel 128 can correspond to the manner in which the potting material 126 flows within the cavity 108.

[0053] At operation 308, after the filling syringe 200 stops injecting the filling material 126 into the cavity 108, for example when the cavity 108 is completely filled with the filling material 126, method 300 includes inserting a plug 130 into the port 118. The plug 130 hermetically seals the cavity 108 to the exterior of the housing 102. For example, the plug 130 may comprise a composite material configured to hermetically seal the port 118 of the cap 106 via friction welding between the plug 130 and a composite material of the core 124 of the cap 116. In another example, the plug 130 may comprise a metallic material configured to hermetically seal the port 118 of the cap 106 via friction welding between the plug 130 and at least one of the outer plate 120 and inner plate 122 of the cap 116. The hermetically sealed cavity 108 allows the filling material 126 to expand, solidify, and solidify without escaping from the cavity 108. In addition, the airtight sealed cavity 108 also seals the battery module 114 within the cavity 108. The potting material 126 can also fix one or more battery modules 114 within the cavity after the potting material 126 has cured and solidified.

[0054] When the filling syringe 200 is operated to inject the filling material 126 into the cavity 108, the port 118 can provide a reference point or benchmark for an optical sensor or sensing system that positions the filling syringe 200 at the RESS assembly 100. Furthermore, the plug 130 can provide a reference point or benchmark for the optical sensor or sensing system during other manufacturing processes, such as during the installation of the RESS assembly 100 at the vehicle 10. That is, because the port 118 and the plug 130 provide relatively high visual contrast compared to the outer surface of the cap 106, the optical system can easily identify and position the port 118 and the plug 130 relative to other parts of the RESS assembly 100. Additionally, the optical sensor or sensing system can detect leakage of the filling material 126 on the outer surface of the cap 106 at or near the plug 130. Because the potting material 126 is injected into the RESS assembly 100 at relatively few locations (i.e., port 118) and the cap 106 is sealed to the housing 104, this allows for faster and simpler verification than a typical manufacturing process, in which the entire periphery of the battery assembly can be visually inspected for leaks.

[0055] Furthermore, because the potting material 126 is injected into the cavity 108 of the housing 102 after the cap 106 is attached to the housing portion 104, the attachment can be performed using a process that does not take into account the thermal limitations of the potting material 126. In other words, the cap 106 can be attached to the housing portion 104 using a process that exposes the housing 102 to temperatures unsuitable for the potting material 126, since the potting material 126 can be injected into the housing 102 after these processes have occurred. For example, the cap 106 can be attached to the housing portion 104 via an adhesive that is heat-cured by placing the housing 102 in an oven.

[0056] Alternatively, the cover of the RESS component may comprise a single material, such as a metal substrate. For example, and specifically referring to... Figure 7 and Figure 8 The RESS component 100a includes a cover 106a, which includes a cover body 116a, wherein the cover body 116a comprises only metallic material and contains no composite material. Given that the components associated with the RESS component 100 are substantially similar in structure and function, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same components, while the same reference numerals including alphanumeric extensions are used to identify those components that have been modified.

[0057] The metallic material of the cover 116a is configured to maintain the rigidity and structure of the cover 106a. Furthermore, the cover 116a lacks plates, cores, and flow channels. Therefore, when potting material 126 is injected through port 118, the potting material 126 flows freely within the cavity 108a of the housing 102a. The cavity 108a adjacent to the cover 116a, lacking flow channels, can be larger than the cavity 108 adjacent to the cover 116, which includes flow channels 128. This allows the potting material 126 to adequately encapsulate the battery module 114 and flow throughout the cavity 108a. Additionally, the RESS assembly 100a includes a plug 130a configured to be disposed within the port 118 of the cover 106a. The plug 130a can be a mechanical thermal fastener, such as a blind rivet, a hollow rivet, etc. The plug 130a may include a metallic material configured to hermetically seal the port 118 of the cap 106a via a mechanical fastening between the plug 130a and the metallic material of the cap 116a. In this respect, after the plug 130a is disposed at the port 118, the cavity 108a of the RESS assembly 100a is hermetically sealed to the exterior of the housing 102a.

[0058] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Therefore, other embodiments are within the scope of the appended claims.

[0059] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in selected configurations, even if not specifically shown or described. They can also be varied in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A rechargeable energy storage system (RESS) component, comprising: Battery module; A housing that houses the battery module within a cavity, the housing including a shell portion and a cover engaged with the shell portion to define the cavity, the cover over and extending along at least a portion of the cavity, the cover including a cover body and a port extending through the cover body and configured to fluidly connect the cavity and the exterior of the housing; A potting material is injected into the cavity through the port, and the potting material flows within the cavity and between the cover and the battery module; and A plug is disposed within the port of the cover and hermetically seals the cavity relative to the outside of the housing.

2. The RESS component according to claim 1, wherein, The cover includes an outer plate, an inner plate, and a core disposed between the outer plate and the inner plate.

3. The RESS component according to claim 2, wherein, The outer panel and the inner panel are made of metallic materials, and the core is made of composite materials.

4. The RESS component according to claim 3, wherein, The plug comprises a composite material and is configured to hermetically seal the port of the cap via friction welding between the plug and the composite material of the cap core.

5. The RESS component according to claim 3, wherein, The plug comprises a metallic material and is configured to hermetically seal the port of the cap via friction welding between the plug and the metallic material of at least one of the outer and inner plates.

6. The RESS component according to claim 2, wherein, The inner plate of the cover includes a flow channel extending from the port for guiding the flow of potting material injected into the cavity.

7. The RESS component according to claim 1, wherein, The cover is made of metal.

8. The RESS component according to claim 7, wherein, The plug comprises a metallic material and is configured to hermetically seal the port of the cap via a mechanical fastening between the plug and the metallic material of the cap.

9. The RESS component according to claim 1, wherein, The port includes a plurality of ports extending through the cover at discrete locations, and wherein the plug includes a plurality of plugs, each of the plurality of plugs being disposed within a corresponding port of the plurality of ports to hermetically seal the cavity.

10. The RESS component according to claim 1, wherein, The cover is welded to the shell.

Images