Battery module with integrated cold plate

Abstract

A rechargeable energy storage system (RESS) of a vehicle includes a plurality of battery cells and a battery enclosure configured to house the plurality of battery cells. The battery enclosure includes an enclosure housing formed from a plurality of assembled metal components and a cold plate mounted to at least one side of the enclosure housing. The cold plate is in thermal communication with the plurality of battery cells to cool the plurality of battery cells disposed in the enclosure housing.

Description

Technical Field

[0001] This disclosure relates to vehicles, and more particularly to rechargeable energy storage systems (RESS) or battery systems for vehicles. Background Technology

[0002] A rechargeable energy storage system (RESS) is used to provide electricity to vehicle systems to power vehicle operation and other functions. The RESS is connected to the vehicle. A RESS typically consists of multiple battery cells housed within a battery casing. The battery cells and the battery casing together constitute the RESS. A cooling system is typically used to maintain a selected temperature for the battery cells within the battery casing. Furthermore, the battery casing is usually sealed to maintain a selected pressure for the battery cells within the casing. Traditional cooling systems are often complex and limit the choice of assembly sequence for the RESS structure. Summary of the Invention

[0003] In one exemplary embodiment, the vehicle's rechargeable energy storage system (RESS) includes a plurality of battery cells and a battery housing configured to house the plurality of battery cells. The battery housing includes a housing formed of a plurality of assembled metal parts and a cold plate mounted to at least one side of the housing. The cold plate is in thermal communication with the plurality of battery cells to cool the plurality of battery cells disposed within the housing.

[0004] In addition to one or more features described herein, the housing also includes a housing base, a housing cover spaced apart from the housing base, and a plurality of housing sidewalls extending between the housing base and the housing cover. A cold plate is located on the housing base.

[0005] In addition to one or more features described herein, the housing base includes one or more base openings to improve thermal contact between the cold plate and the multiple battery cells.

[0006] In addition to one or more features described herein, one or more spacers extend between the two outer shell sidewalls of the housing.

[0007] In addition to one or more features described herein, the housing is formed by one or more of spot welding, laser welding, MIG welding, riveting, or self-piercing riveting.

[0008] In addition to one or more features described herein, the cold plate also includes a fluid inlet, a fluid outlet, and one or more fluid channels that extend through the cold plate between the fluid inlet and the fluid outlet.

[0009] In addition to one or more features described herein, the housing also includes one or more sidewall recesses. At least one of the fluid inlet and fluid outlet is located at a sidewall recess of one or more sidewall recesses.

[0010] In addition to one or more features described herein, the plurality of battery cells are plurality of prismatic battery cells.

[0011] In another exemplary embodiment, a vehicle includes a body, a powertrain located at the body to drive the vehicle, and a rechargeable energy storage system (RESS) operatively connected to the powertrain. The RESS includes a plurality of battery cells and a battery housing configured to house the plurality of battery cells. The battery housing includes a housing formed of a plurality of assembled metal parts and a cold plate mounted to at least one side of the housing. The cold plate is positioned in thermal communication with the plurality of battery cells to cool the plurality of battery cells disposed within the housing.

[0012] In addition to one or more features described herein, the housing also includes a housing base, a housing cover spaced apart from the housing base, and a plurality of housing sidewalls extending between the housing base and the housing cover. A cold plate is located on the housing base.

[0013] In addition to one or more features described herein, the housing base also includes one or more base openings to improve thermal contact between the cold plate and the multiple battery cells.

[0014] In addition to one or more features described herein, one or more separators extend between the two outer shell sidewalls of the housing.

[0015] In addition to one or more features described herein, the housing is formed by one or more of spot welding, laser welding, MIG welding, riveting, or self-piercing riveting.

[0016] In addition to one or more features described herein, the cold plate also includes a fluid inlet, a fluid outlet, and one or more fluid channels extending through the cold plate between the fluid inlet and the fluid outlet.

[0017] In addition to one or more features described herein, the housing also includes one or more sidewall recesses. At least one of the fluid inlet and fluid outlet is located at a sidewall recess of one or more sidewall recesses.

[0018] In addition to one or more features described herein, the plurality of battery cells are plurality of prismatic battery cells.

[0019] In another exemplary embodiment, the assembly method of the rechargeable energy storage system (RESS) includes forming a plurality of components into a housing, arranging and assembling the housing by the plurality of components, and securing a cold plate to the housing. After securing the cold plate to the housing, a plurality of battery cells are installed into the housing. The cold plate is positioned to be in thermal contact with the plurality of battery cells.

[0020] In addition to one or more features described herein, multiple components are formed by one of stamping or bending.

[0021] In addition to one or more features described herein, the outer shell is assembled into a rectangular cuboid.

[0022] In addition to one or more features described herein, the housing is assembled by one or more of spot welding, laser welding, MIG welding, riveting, or self-piercing riveting.

[0023] The above-described features and advantages, as well as other features and advantages of the present invention, will become apparent from the following detailed description taken in conjunction with the accompanying drawings. Attached Figure Description

[0024] Other features, advantages, and details appear by way of example only in the following detailed description, which is illustrated in the accompanying drawings, wherein:

[0025] Figure 1 This is a side view of an exemplary embodiment of the vehicle;

[0026] Figure 2 This is a cross-sectional view of an embodiment of a vehicle's rechargeable energy storage system (RESS);

[0027] Figure 3 This is a cross-sectional view of one embodiment of the RESS housing;

[0028] Figure 4 This is a schematic diagram of one embodiment of the RESS assembly method. Detailed Implementation

[0029] The following description is merely exemplary in nature and is not intended to limit the invention or its application or use. It should be understood that in all the drawings, corresponding reference numerals denote the same or corresponding parts and features.

[0030] According to an exemplary embodiment, and according to a non-limiting example, the vehicle in Figure 1 The vehicle 10 is generally designated as 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. In a non-limiting example, two of the plurality of wheels 16 are steerable. The body 12 partially defines a passenger compartment 14 having seats 22 located behind an instrument panel 26. A steering controller 30 is disposed between the seats 22 and the instrument panel 26. The steering controller 30 is operated to control the direction of the steering wheels 16. A powertrain 28 is operatively connected to the plurality of wheels 16 and one or more components of the powertrain 28. A rechargeable energy storage system (RESS) 32 is operatively connected to the powertrain 28, and in some embodiments, to other components or systems of the vehicle 10. The RESS 32 provides electricity to the powertrain 28 for propelling the vehicle 10.

[0031] For reference Figure 2 The RESS 32 includes a plurality of battery cells 34 located within a battery housing 36. In some embodiments, the battery cells 34 are prismatic battery cells 34, but this is merely exemplary. Those skilled in the art will readily understand that other types of battery cells 34 can be used in the RESS 32. The battery housing 36 includes a housing shell 38 formed of a metallic material such as steel or aluminum, and includes a housing base 40, a housing cover 42, and a plurality of housing sidewalls 44 extending between the housing base 40 and the housing cover 42. Figure 3 (Best shown in the diagram). Although in some embodiments the housing base 40, housing cover 42 and housing sidewall 44 are formed of the same material, in other embodiments the material and / or material properties, such as material thickness, may vary among the components of the housing 38.

[0032] In some embodiments, the housing base 40 and housing cover 42 are substantially rectangular, and therefore the final housing 38 is substantially a rectangular cuboid. Those skilled in the art will readily understand that the housing 38 can be other three-dimensional shapes. The housing 38 components can be assembled using one or more of a variety of methods, including spot welding, laser welding, MIG welding, riveting, or self-piercing riveting.

[0033] The battery housing 36 also includes a cold plate 46 fixed to the housing 38, for example, at the housing base 40. The cold plate 46 is fixed to the housing 38 by one or more methods, including spot welding, laser welding, MIG welding, riveting, or self-piercing riveting. The cold plate 46 includes a fluid inlet 48 and a fluid outlet 50 (in... Figure 3 (best shown in the diagram), and one or more fluid flow channels 52 extend through the cold plate 46 between the fluid inlet 48 and the fluid outlet 50. Cooling fluid, such as refrigerant, circulates through the fluid flow channels 52 to cool the plurality of battery cells 34 disposed inside the housing 38.

[0034] For reference Figure 3 To improve thermal contact between the cold plate 46 and the battery cells 34, the housing base 40 includes one or more base openings 54. The one or more base openings 54 allow direct contact between at least some of the battery cells 34 and the cold plate 46 to improve the cooling performance of the cold plate 46. Also... Figure 3As shown, the housing 38 may include, for example, one or more housing recesses 56 in one or more housing sidewalls 44 to receive a fluid inlet 48 and / or a fluid outlet 50. Furthermore, the housing 38 may have one or more partitions 58 disposed therein and fixed to the housing sidewalls 44. The one or more partitions 58 are configured and positioned to support the housing sidewalls 44 and the housing cover 42, and to increase the strength of the housing 38. In addition to improving the contact between the cold plate 46 and the battery cell 34, the base opening 54 allows the housing 38 to be assembled into a unit before the battery cell 34 is installed into the housing 38 via the base opening 54. In some embodiments, a thermal interface material layer 60 (such as...) Figure 2 (As shown) is disposed between the battery cell 34 and the cold plate 46 to further improve the thermal performance of the cold plate 46.

[0035] An exemplary method for assembling RESS 32 is as follows: Figure 4 As shown. In step 100, components of the housing 38 are formed, for example, by stamping or bending. In step 102, the components of the housing 38 are arranged and secured to define the housing 38. In step 104, a cold plate 46 is mounted to the housing 38 and secured thereto by a selected method. After the cold plate 46 is mounted to the housing 38, in step 106, a plurality of battery cells 34 are mounted into the housing 38.

[0036] The RESS 32 configuration disclosed herein allows for pre-assembly of the housing 38, thereby simplifying the overall manufacturing process of the RESS 32 and reducing waste and potential environmental waste. Furthermore, it supports various fastening methods, including spot welding, laser welding, MIG welding, riveting, and self-piercing riveting, providing versatility in assembly. The disclosed configuration also supports flexible construction techniques, such as stamping or bending, to adapt to various production requirements. In addition, this construction design provides a low-cost manufacturing method, reducing production costs and allowing for leak testing of the cold plate 46 before the completion of the RESS 32 assembly. Moreover, the structure can be constructed using similar or dissimilar materials, enhancing design and manufacturing flexibility. The modularity of the RESS 32 configuration allows for maintenance at the module level, enhancing maintainability and extending the battery system's lifespan.

[0037] The terms “a” and “an” do not indicate a quantity limitation, but rather the presence of at least one of the referred items. The term “or” means “and / or”, unless the context clearly indicates otherwise. Throughout the specification, reference to “an aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner across the aspects.

[0038] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it may be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being "directly on another element," there are no intermediate elements present.

[0039] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0040] While the above disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made thereto and equivalent substitutions can be made to its elements without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from its essential scope. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A rechargeable energy storage system (RESS) for a vehicle, comprising: Multiple battery cells; and A battery casing, configured to house multiple battery cells, includes: A housing formed by multiple assembled metal parts; and A cold plate is installed on at least one side of the housing, and the cold plate is in thermal communication with the plurality of battery cells to cool the plurality of battery cells disposed in the housing.

2. The rechargeable energy storage system according to claim 1, wherein, The outer casing includes: outer casing base; The housing cover is spaced apart from the housing base; and Multiple housing sidewalls extending between the housing base and the housing cover; The cold plate is mounted on the base of the outer casing.

3. The rechargeable energy storage system according to claim 2, wherein, The housing base includes one or more base openings to improve thermal contact between the cold plate and the plurality of battery cells.

4. The rechargeable energy storage system of claim 2, further comprising one or more spacers extending between the two outer casing sidewalls of the outer casing.

5. The rechargeable energy storage system according to claim 2, wherein, The outer shell is formed by one or more of the following methods: spot welding, laser welding, MIG welding, riveting, or self-piercing riveting.

6. The rechargeable energy storage system according to claim 1, wherein, The cold plate includes: fluid inlet; Fluid outlet; and One or more fluid channels extend through the cold plate between the fluid inlet and the fluid outlet.

7. The rechargeable energy storage system according to claim 6, wherein, The housing includes one or more sidewall recesses, and at least one of the fluid inlet and the fluid outlet is disposed in the sidewall recess of the one or more sidewall recesses.

8. The rechargeable energy storage system according to claim 1, wherein the plurality of battery cells are a plurality of prismatic battery cells.

9. A vehicle comprising: Body; The power system mounted on the vehicle body to drive the vehicle's movement; and The rechargeable energy storage system (RESS) according to any one of claims 1-8 is operatively connected to the power system.

10. A method for assembling a rechargeable energy storage system (RESS), comprising: Multiple components that form the outer shell; The outer casing is arranged and assembled from multiple components; Secure the cold plate to the outer casing; and After the cold plate is fixed to the housing, multiple battery cells are installed into the housing, and the cold plate is positioned to make thermal contact with the multiple battery cells.

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