Multilayer top cover for a battery pack

Abstract

The present disclosure provides a top cover for a battery pack and a battery pack, wherein the top cover is configured to be attached to a battery pack comprising a plurality of battery arrays and substantially forms a top cover for the battery arrays within the battery pack. The top cover comprises a first wall, a second wall, and a third wall, the first wall and the second wall being spaced apart from each other to form a first hollow portion, the second wall and the third wall being spaced apart from each other to form a second hollow portion. The first wall forms at least a portion of a top cover for each of the plurality of battery arrays, the first wall comprising at least one vent inlet and at least one vent outlet to atmosphere such that the first hollow portion provides a fluid flow path between the at least one vent inlet and the at least one vent outlet, and the second hollow portion is not in fluid communication with the first hollow portion.

Description

Technical Field

[0001] This disclosure relates to battery systems for electric vehicles, and more specifically, to a battery pack top cover design integrated with a battery array cover to manage battery cell ventilation and heat transfer. Background Technology

[0002] Battery systems for electric vehicles typically include multiple battery cells arranged in battery modules and battery packs to provide the required voltage and capacity.

[0003] Traditional battery pack designs typically utilize separate module housings and a battery pack enclosure. The module housings contain and protect the cluster of battery cells, while the battery pack enclosure provides overall structural support and environmental protection. This multi-layered approach to battery systems can be relatively heavy and complex.

[0004] If a battery cell experiences thermal runaway, it can release hot gases and particles. Typical venting solutions involve dedicated venting channels and ports within the battery module and battery pack housing. There are also challenges in effectively directing the vents away from other battery cells and electrical components. Summary of the Invention

[0005] The present invention is provided to present selected concepts in a simplified form, which will be further described in the following detailed description.

[0006] In a first aspect, a top cover for a battery pack is provided. The top cover is configured to attach to a battery pack comprising a plurality of battery arrays and substantially forms a top cover for the battery arrays within the battery pack. The top cover includes a first wall, a second wall, and a third wall. The first wall and the second wall are spaced apart from each other to form a first hollow portion, and the second wall and the third wall are spaced apart from each other to form a second hollow portion. The first wall forms at least a portion of the top cover for each of the plurality of battery arrays. The top cover includes at least one vent inlet and at least one vent outlet opening to the atmosphere, such that the first hollow portion provides a fluid flow path between the at least one vent inlet and the at least one vent outlet. The second hollow portion is not in fluid communication with the first hollow portion.

[0007] This multi-layered top cover design provides effective management of gases from battery cells that have experienced thermal runaway, thereby isolating hot exhaust gases from sensitive battery components.

[0008] At least one ventilation inlet can pass through the second wall.

[0009] This design allows for controlled exhaust into the first hollow section, providing an unobstructed path for gas flow while maintaining separation between the gas-containing space and other battery components.

[0010] The shape of the second wall allows the first hollow portion to be divided into multiple chambers.

[0011] Dividing the first hollow section into multiple chambers allows for more localized gas management, potentially limiting the diffusion of hot gases to specific areas of the battery pack.

[0012] The multiple chambers in the first hollow section may not be fluidly connected to each other.

[0013] This feature further enhances the isolation of exhaust gases, prevents cross-contamination between different parts of the battery pack, and potentially limits the extent of thermal events.

[0014] Each chamber can be substantially aligned with the battery array.

[0015] Aligning the chambers with specific battery arrays allows for targeted gas management, potentially improving the efficiency of exhaust and thermal management for individual arrays.

[0016] Each corresponding battery array is in fluid communication with a corresponding chamber in the top cover.

[0017] This direct connection between the array and the chamber ensures that the exhaust has an unobstructed and dedicated escape path, thereby potentially reducing pressure build-up within the individual arrays.

[0018] Each battery array may include a separate vent to the corresponding chamber of the top cover.

[0019] Providing each array with a separate vent allows for independent venting of individual arrays, potentially improving the overall gas management capabilities of the battery pack.

[0020] The second hollow section can be configured to accommodate busbars or wiring.

[0021] Using the second hollow section for busbars or wiring allows for efficient use of space within the battery pack.

[0022] Each of the at least one ventilation inlet may include a burst zone.

[0023] Including a bursting zone in the vent allows gas to enter the first hollow section only when a specific pressure threshold is reached.

[0024] Each burst area may include fragile parts.

[0025] Using fragile parts in the burst zone ensures a predictable and reliable opening mechanism for gas venting.

[0026] The fragile parts can be configured to break at a predetermined pressure level.

[0027] Designing the fragile components to break at specific pressure levels allows for precise control over when venting occurs, potentially preventing premature venting or excessive pressure buildup.

[0028] At least one vent may include a one-way valve.

[0029] A one-way valve is incorporated into the vent inlet to prevent gas backflow, thereby ensuring that the exhaust follows the intended path through the first hollow section and exits the battery pack.

[0030] The opposing surfaces of the second and third walls may be coated with silicate minerals.

[0031] Coating surfaces with silicate minerals can provide additional insulation and fire resistance.

[0032] In a second aspect, a battery pack is provided. The battery pack includes a top cover from the first aspect and at least one battery array.

[0033] Integrating the top cover design with the battery pack creates a comprehensive system for managing thermal events and venting.

[0034] In a third aspect, a vehicle is provided. The vehicle includes the battery pack of the second aspect. Attached Figure Description

[0035] Non-restrictive and non-exhaustive examples are described with reference to the following figures.

[0036] Figure 1A The battery pack, including the top cover as described herein, is shown. Figure 1B A battery pack including a top cover assembled according to the portions described herein is shown; Figure 1C A battery pack, including portions assembled according to the top cover described herein, is shown. Figure 2 Another battery pack is shown, including the top cover as described herein; Figure 3 This shows another battery pack including the top cover as described herein; and Figure 4 A vehicle containing a battery pack including a top cover as described herein is shown.

[0037] Use common reference numerals in all the accompanying drawings to indicate similar features. Detailed Implementation

[0038] This disclosure relates to a top cover for a battery pack. The top cover is configured to be attached to a battery pack comprising a plurality of battery arrays. The top cover essentially forms a top cover for the battery arrays within the battery pack.

[0039] The top cover comprises multiple layers that create separate spaces or hollow sections. These hollow sections serve different purposes; one hollow section provides a path for venting gas from the battery array, while another hollow section can be used for other components or purposes.

[0040] This multi-layered design offers several advantages in managing cell venting and heat transfer within the battery pack. By providing dedicated space for venting gases, the top cover helps direct hot exhaust gases away from the modules and other battery array components.

[0041] The top cover can be integrated into various types of battery packs, including those used in electric vehicles. A battery pack including the disclosed top cover and at least one battery array can be installed in a vehicle.

[0042] The top cover includes a first wall that forms at least a portion of the top cover for each battery array within the battery pack. The first wall plays a crucial role in managing gas flow within the battery pack.

[0043] The top cover includes at least one vent inlet and at least one vent outlet. The vent inlet allows gases generated within the battery array to enter the space within the top cover. The vent outlet provides a path for these gases to exit the top cover and be discharged into the atmosphere.

[0044] A first hollow section is formed between a vent inlet and a vent outlet. This first hollow section provides a fluid flow path connecting the vent inlet to the vent outlet. This arrangement allows gas from the battery array to enter through the vent inlet, travel through the first hollow section, and then exit through the vent outlet.

[0045] By combining these features, the first wall of the top cover facilitates the controlled venting of gases from the battery array. This design helps manage thermal events within the battery pack by providing a designated path for guiding hot gases away from sensitive components and other battery array elements.

[0046] The top cover includes a second wall positioned relative to the first wall. The second wall and the first wall are spaced apart from each other, forming a first hollow portion between them. This arrangement creates a defined space within the top cover for gas flow.

[0047] In some examples, the shape of the second wall can divide the first hollow portion into multiple chambers. This configuration can provide different pathways or compartments within the first hollow portion, potentially allowing for more controlled gas flow management within the top cover.

[0048] The second wall may include features extending through it, such as ventilation inlets. These ventilation inlets provide a path for gas to enter the first hollow section from the battery array below. By positioning the ventilation inlets within the second wall, gas can be directed to specific areas of the first hollow section.

[0049] In a particular configuration, the multiple chambers created by the shape of the second wall may not be in fluid communication with each other. This separation allows for isolated gas flow paths within the first hollow section, potentially corresponding to different sections or arrays of the battery pack.

[0050] The design of the second wall, including its shape and any features passing through it, contributes to the overall gas management capabilities of the top cover. By creating multiple chambers and controlling the flow of gas through the vents, the second wall guides and manages the gas within the battery pack.

[0051] The top cover includes a third wall positioned relative to the second wall. The third wall and the second wall are spaced apart from each other, forming a second hollow portion between them. This second hollow portion is different from and separate from the first hollow portion formed between the first wall and the second wall.

[0052] The second hollow section is not in fluid communication with the first hollow section. This isolation ensures that the second hollow section remains separate from the gas flow path provided by the first hollow section. This separation of the two hollow sections allows for different functions to be achieved within the top cover structure.

[0053] In some examples, the second hollow section can be configured to house the various components of the battery pack. For instance, the second hollow section can provide space for busbars or wiring. This arrangement allows electrical components to be integrated within the top cover structure while maintaining isolation between the electrical components and the gas flow path.

[0054] The opposing surfaces of the second and third walls may be coated with silicate minerals. This coating can provide additional protection or insulation for components housed within the second hollow section. The silicate mineral coating can also contribute to the overall thermal management capabilities of the top cover.

[0055] By incorporating this third wall and creating a separate second hollow section, the top cover design allows for a multi-functional structure that manages gas flow while also providing protective space for other battery pack components.

[0056] The top cover includes a first hollow portion formed between a first wall and a second wall. This first hollow portion serves as a key component in the gas management system of the battery pack. The first hollow portion provides a fluid flow path connecting a vent inlet to a vent outlet, thereby allowing the controlled movement of gases generated within the battery array.

[0057] In some examples, the first hollow section can be divided into multiple chambers. These chambers can be substantially aligned with individual battery arrays within the battery pack. This alignment allows for more targeted gas management methods because each chamber can correspond to a specific battery array or group of arrays.

[0058] Each battery array may include a separate vent to a corresponding chamber of the top cover. This configuration allows gas generated by a particular battery array to be directed into a designated chamber within the first hollow portion. By providing an independent vent for each battery array, the top cover can simultaneously manage gas flow from multiple sources.

[0059] The design of the first hollow section ensures that each battery array is in fluid communication with a separate chamber in the top cover. This fluid communication allows gas generated by the battery array to flow freely into the corresponding chamber of the first hollow section. From there, the gas can be guided along a fluid flow path toward the vent.

[0060] The structure of the first hollow section, formed by the first and second walls, creates a dedicated space within the top cover for gas flow. This space is separated from other components of the battery pack, helping to isolate potentially hot or corrosive gases from the electrical components. The design of the first hollow section contributes to the overall thermal management of the battery pack by providing a controlled path for venting.

[0061] The top cover includes a second hollow portion formed between the second and third walls. This second hollow portion is different from and separate from the first hollow portion formed between the first and second walls. The second hollow portion is not in fluid communication with the first hollow portion, ensuring complete isolation between the two spaces within the top cover structure.

[0062] The second hollow section can be configured to house various components of the battery pack. For example, the second hollow section can provide space for busbars or wiring. This arrangement allows electrical components to be integrated within the top cover structure while maintaining isolation between the electrical components and the gas flow path in the first hollow section.

[0063] In some examples, if the space is fully sealed, the space within the second hollow section can be cooled by fluid. This cooling feature can help manage the temperature of the components housed within the second hollow section, potentially improving the overall thermal management of the battery pack.

[0064] The opposing surfaces of the second and third walls may be coated with silicate minerals. This coating can provide additional protection or insulation for components housed within the second hollow section. The silicate mineral coating can also contribute to the overall thermal management capabilities of the top cover.

[0065] By incorporating this separate second hollow section, the top cover design allows for a multi-functional structure that manages gas flow in the first hollow section while also providing a protected space for other battery pack components in the second hollow section.

[0066] The top cover includes at least one vent inlet and at least one vent outlet. The vent inlet allows gases generated within the battery array to enter the first hollow portion of the top cover. The vent outlet provides a path for these gases to exit the top cover and be discharged into the atmosphere.

[0067] In some examples, the vent may include a one-way valve. This one-way valve allows gas to flow from the battery array into the first hollow portion of the top cover, but prevents gas or other substances from flowing back into the battery array. The one-way valve may be designed to open at a specific pressure, ensuring that gas is released only when necessary.

[0068] Each vent may include a burst zone. The burst zone is designed to rupture or open when exposed to a specific level of pressure, thereby allowing gas to flow through the vent and into the first hollow section of the top cover.

[0069] The burst zone may include a fragile section. This fragile section is a weakened or specially designed area of ​​the burst zone, constructed to rupture at a predetermined pressure level. When the pressure within the battery array reaches this predetermined level, the fragile section ruptures, thereby creating an opening for gas flow through the vent inlet.

[0070] The predetermined pressure level for the fragile component to break can be selected based on various factors, such as the specifications of the battery cells and the overall design of the battery pack. By carefully selecting this pressure level, the top cover can be designed to vent at appropriate points during thermal events, thereby helping to manage pressure build-up within the battery pack.

[0071] The battery pack 250 includes a top cover 110, which is configured to be attached to the battery pack 250 and substantially form a top cover for a plurality of battery arrays 180 within the battery pack 250. Figure 1A A cross-sectional view of the battery pack top cover assembly is shown.

[0072] The top cover 110 includes a first wall 115, a second wall 122, and a third wall 125. The first wall 115 and the second wall 122 are spaced apart from each other to form a first hollow portion 120. The second wall 122 and the third wall 125 are spaced apart from each other to form a second hollow portion 182.

[0073] The first wall 115 forms at least a portion of the top cover of each of the plurality of battery arrays 180. The top cover 110 includes at least one vent inlet 140 and at least one vent outlet to the atmosphere. A first hollow portion 120 provides a fluid flow path between the at least one vent inlet 140 and the at least one vent outlet. A second hollow portion 182 is not in fluid communication with the first hollow portion 120.

[0074] Figure 1AA cooling plate 170 located at the bottom of the assembly is shown. A transverse member 185 of the battery pack provides structural support and allows controlled fluid flow 190 in the direction indicated by the fluid flow direction 195.

[0075] Figure 1B This shows the decomposed state of multiple layers in the design of the top cover 110. Figure 1C Another cross-sectional view of the battery pack assembly is shown, illustrating the integration of multiple layers in the top cover 110 design. The arrangement of the walls creates separate chambers, where the first hollow portion 120 and the second hollow portion 182 provide dedicated space for fluid movement. A vent 140 enables controlled gas movement between the chambers while maintaining the structural integrity of the battery pack 250.

[0076] Figure 1C Showing something similar to Figure 1B A cross-sectional view of the battery pack assembly, but showing a single vent 140 through the structure. The walls are arranged to create separate chambers, where a first hollow portion 120 and a second hollow portion 182 provide dedicated space.

[0077] The first wall 115 can be made of steel, aluminum, or any suitable material. The layered construction of the top cover 110 illustrates how the first wall 115, the second wall 122, and the third wall 125 can be arranged to create separate spaces while maintaining the overall structure of the battery pack assembly. This design allows for gas management through designated paths within the assembly.

[0078] Figure 2 The alternative construction is shown in the figure. Figure 2 A cross-sectional view of the battery pack assembly is shown, illustrating the integration of multiple walls forming the top cover structure. The battery pack 250 includes a top cover 210, which includes three distinct walls arranged to create separate hollow sections.

[0079] The component includes a first wall 215 forming the uppermost layer, below which a first hollow portion 220 is located. A second wall 222 is arranged below the first hollow portion 220, followed by a third wall 225, creating different spaces within the component.

[0080] Ventilation inlet 240 passes through the aforementioned structure. In this configuration, ventilation inlet 240 passes through the second wall 222, which is consistent with... Figure 1A , Figure 1B and Figure 1C The ventilation inlet 140 shown is arranged through the second wall 222 in the same manner. Alternatively or optionally, the first wall may include a ventilation inlet and a ventilation outlet to the atmosphere.

[0081] Cooling plate 270 is located at the lower part of the module, and battery array 280 is located above cooling plate 270. Second hollow portion 282 is formed adjacent to battery array 280. Transverse members 285 of the battery pack provide structural support for the module.

[0082] The walls are arranged to create separate chambers, with the first hollow portion 220 and the second hollow portion 282 providing dedicated space. Fluid flow 290 moves through a designated path within the assembly, as indicated by the flow direction 295. This fluid flow arrangement is similar to... Figure 1A The arrangement shown is different, but with a more clearly defined path through the first hollow portion 220.

[0083] The shape of the second wall 222 divides the first hollow portion 220 into multiple chambers. These multiple chambers of the first hollow portion 220 are not in fluid communication with each other, thereby providing isolation between different sections of the battery pack 250.

[0084] Each chamber of the first hollow portion 220 may be substantially aligned with the battery array 280. This alignment allows each battery array 280 to be in fluid communication with a corresponding chamber of the top cover 210. Furthermore, each battery array 280 may include a separate vent 240 for access to a corresponding chamber of the top cover 210, thereby enhancing the individual venting capability of each array.

[0085] Depending on the specific design requirements and integration needs of the battery system, the top cover 210 can be fixed to the battery pack 250 using various methods such as adhesives, fasteners, or welding.

[0086] The first wall 215 forms part of the upper surface of the battery pack 250, contributing to the overall structural integrity of the assembly. This configuration illustrates how the first wall 215, the second wall 222, and the third wall 225 are arranged to create separate spaces while maintaining the overall structural integrity of the battery pack assembly. This design allows controlled fluid movement through designated paths within the assembly, thereby providing effective management of thermal events and venting processes.

[0087] Figure 3 Another arrangement is shown in the diagram. Figure 3 A cross-sectional view of the battery pack assembly is shown, illustrating the integrated multi-layered top cover structure. The battery pack 250 includes a top cover 310, which includes three distinct walls arranged to create separate hollow sections.

[0088] The component includes a first wall 315 forming the uppermost layer, beneath which a first hollow portion 320 is located. A second wall 322 is arranged below the first hollow portion 320, followed by a third wall 325, thereby creating different spaces within the component. This arrangement is similar to the structure shown in the previous figures, but with some significant differences.

[0089] Ventilation inlet 340 passes through this structure, similar to Figure 1A , Figure 1B and Figure 2The configuration is shown. The vent inlet 340 may include a burst region. In some examples, the burst region includes a fragile portion. The fragile portion may be configured to rupture at a predetermined pressure level. In a particular configuration, the vent inlet 340 may include a one-way valve.

[0090] A cooling plate 370 is located at the lower part of the assembly, and a battery array 380 is located above the cooling plate 370. A second hollow portion 382 is formed adjacent to the battery array 380. These components are arranged as shown in the previous figures.

[0091] Figure 3 Several new features not present in the preceding figures are introduced. Cover layer 384 is shown providing additional structural support for the assembly. This cover layer 384 enhances the overall integrity of the battery pack 250.

[0092] There is also a battery pack lateral member 385, which helps maintain the structural integrity of the assembly. The battery pack lateral member 385 performs a similar function to the battery pack lateral member shown in the previous figure.

[0093] Figure 3 A unique feature of the component shown is the channel 386 for busbars or cables within the component. This channel illustrates how the second hollow portion 382 can be configured to accommodate busbars or wiring, thereby providing dedicated space for electrical components within a multi-layer structure.

[0094] The accompanying figure also illustrates a fluid flow path 390 established through designated pathways within the component. This fluid flow 390 is similar to the fluid flow pattern shown in the previous figures, demonstrating a consistent design principle for controlled gas management throughout various constructions.

[0095] Figure 3 A unique illustration shows thermal events 395 occurring within the structure. This depiction demonstrates how the multi-layered top cover design manages and accommodates thermal events within the battery pack 250.

[0096] The first hollow section 320 may contain a burstable fireproof panel for gas venting protection.

[0097] The shape of the second wall 322 can support battery cells of different shapes and sizes. This flexibility in the design of the second wall 322 allows for adaptability to the configuration of the battery array 380 within the battery pack 250.

[0098] In some examples, the opposing surfaces of the second wall 322 and the third wall 325 are coated with silicate minerals. This coating provides additional thermal protection and thermal resistance within the battery pack 250 structure.

[0099] The walls are arranged to create separate chambers, with the first hollow portion 320 and the second hollow portion 382 providing dedicated space. The layered construction illustrates how the first wall 315, the second wall 322, and the third wall 325 are arranged to create separate spaces while maintaining the overall structure of the battery pack assembly.

[0100] Vent outlets can be located at various positions on the top cover to facilitate effective gas venting. These outlets can be designed with specific shapes or sizes to control the rate at which gas flows out of the top cover. In some examples, the vent outlets may also include features such as filters or baffles to prevent debris from entering the top cover while allowing gas to escape.

[0101] The top cover of the battery pack is tightly integrated with the battery array to provide efficient gas management and structural support. In some examples, the top cover includes an array cover portion that is aligned with the individual battery arrays within the battery pack. This alignment allows for targeted gas management and structural support for each array.

[0102] The array cover may include downward-extending walls to hold the battery cells together within each battery array. These walls provide structural support and maintain proper battery cell positioning without requiring additional pressing components within the array itself. Integrating the battery holding function into the top cover simplifies the overall design of the battery pack.

[0103] In some examples, the array cover is designed to be flexible enough to accommodate different battery cell sizes. This design allows for potential future upgrades or changes to the battery pack without requiring a complete redesign of the entire battery pack structure. For example, if needed, the array cover can be configured to accommodate larger battery cells, thus providing a degree of future protection for the battery pack design.

[0104] The top cover can be designed such that each battery array is in fluid communication with a corresponding chamber within the top cover. This arrangement allows gases generated by a particular array to be directed into a designated space within the top cover structure. In some examples, each battery array may include a separate vent to its corresponding chamber within the top cover. This configuration enables independent gas management for each array within the battery pack.

[0105] The integration between the top cover and the battery array may also include features that ensure proper sealing and containment of gases. For example, the junction between the array cover portion and the battery array may include gaskets, seals, or other mechanisms to prevent gas leakage and ensure that exhaust gas is guided through the intended path within the top cover structure.

[0106] By tightly integrating the top cover with the battery array, the overall design of the battery pack enables more efficient gas management, structural support for the battery cells, and flexibility for potential future changes or upgrades to the battery system.

[0107] The top cover of the battery pack integrates multiple components to effectively manage cell venting, control gas flow, and prevent heat transfer. The top cover comprises three walls: a first wall, a second wall, and a third wall. These walls work together to create separate spaces within the top cover structure, each used for a specific purpose within the gas management system.

[0108] The first and second walls form a first hollow section that serves as the primary path for exhaust gases. This first hollow section connects a vent inlet to a vent outlet, thereby allowing controlled movement of gases generated within the battery array. The second and third walls form a second hollow section, which can be used to house electrical components such as busbars or wiring, thereby keeping them isolated from the gas flow path.

[0109] A burstable fireproof panel can be integrated into the top cover design for additional gas venting protection. This panel can be secured to the bottom layer of the top cover before attachment, creating a single component that is easy to mount onto the battery pack. The burstable panel allows for controlled venting of gases in the event of a thermal accident.

[0110] The top cover can be manufactured using a variety of materials, including steel, aluminum, or any suitable material. Material selection may depend on factors such as weight requirements and thermal properties. The manufacturing process of the top cover may involve stamping.

[0111] Various methods can be used to secure the top cover to the battery pack. These methods may include the use of adhesives, fasteners, or welding techniques. The choice of attachment method may depend on factors such as the materials used in the top cover and battery pack structure, as well as specific requirements for sealing and structural integrity.

[0112] The top covers 110, 210, and 310 of the battery pack 250 include a multi-layer structure, which in Figure 1A , Figure 1B , Figure 1C , Figure 2 and Figure 3 The various configurations shown are consistent. This multi-layered structure includes first walls 115, 215, 315, second walls 122, 222, 322, and third walls 125, 225, 325. These walls are arranged to create two distinct hollow portions: a first hollow portion 120, 220, 320 between the first and second walls, and a second hollow portion 182, 282, 382 between the second and third walls.

[0113] First walls 115, 215, 315 form at least a portion of the top cover of each battery array 180, 280, 380 within the battery pack 250. This configuration allows for a uniform top surface while providing individual coverage for each array. The first walls include at least one vent 140, 240, 340, which facilitates the movement of gas from the battery array into the first hollow portion.

[0114] The first hollow sections 120, 220, and 320 serve as dedicated spaces for fluid flows 190, 290, and 390. These fluid flows can be guided through the first hollow sections, thus providing a path for gases or other fluids to move from the vent inlet to a designated outlet area. The fluid flow directions 195 and 295 can be controlled to optimize thermal management within the battery pack.

[0115] The second hollow portions 182, 282, and 382 are separated from the first hollow portion by second walls 122, 222, and 322. This separation creates different spaces that can be used for various purposes. In some configurations, the second hollow portions can be fluid-cooled. This cooling capability enhances the thermal management of the battery pack 250, thereby allowing for more efficient heat dissipation from the battery array.

[0116] The multi-layered structure of the top covers 110, 210, and 310 also offers opportunities for additional functionality. For example, the walls of the top covers can be used to hold the battery cells together within the battery arrays 180, 280, and 380. This structural support can potentially eliminate the need for individual press-fit components within the array, thereby simplifying the overall design and potentially reducing the number of components required.

[0117] Cooling plates 170, 270, and 370 are typically located at the bottom of the module, providing heat dissipation for the battery array. Lateral battery pack members 185, 285, and 385 provide structural support for the module and also facilitate fluid flow management within the battery pack.

[0118] In some constructions, such as Figure 3 As shown, channel 386 for busbars or cables is integrated within the assembly. This channel utilizes the space created by the multi-layered structure to accommodate electrical components, demonstrating the design's versatility.

[0119] The top cover design aids in thermal management by creating dedicated spaces for fluid flow and potential cooling. The first hollow sections 120, 220, and 320 allow for controlled movement of gas or fluid, while the second hollow sections 182, 282, and 382 can be used for additional cooling if needed. Figure 3 As shown, this arrangement helps manage thermal events by providing pathways for heat dissipation and gas exhaust.395

[0120] like Figure 4As shown, a battery pack 250 with a multi-layered top cover is integrated into a vehicle 400, demonstrating how this design contributes to the overall performance of the vehicle. The effective thermal management and structural design of the top cover allow for optimal placement and operation of the battery pack within the vehicle architecture.

[0121] Figure 4 An example of a vehicle is shown, which includes a battery pack with a top cover as described herein. Figure 4 A simplified side orthographic view of a vehicle 400 incorporating a battery pack 250 is shown. The figure illustrates a basic outline representation of the vehicle 400, with the battery pack 250 located within the vehicle's structure.

[0122] The battery pack 250 is shown as a rectangular assembly integrated into the lower part of the vehicle 400. This positioning of the battery pack 250 provides several advantages, such as a low center of gravity and efficient use of space within the vehicle structure.

[0123] Compared to the overall size of the vehicle 400, the battery pack 250 is relatively large, indicating that it is a significant component of the vehicle architecture. The battery pack 250 extends over a considerable portion of the vehicle's length and occupies a large portion of the vehicle's chassis area.

[0124] The structure of the battery pack 250 integrated into the vehicle 400 illustrates how the top cover, as described in the preceding figures, forms an integrated part of the vehicle design. The top cover of the battery pack 250 can serve as part of the floor of the vehicle 400.

[0125] These components and features are integrated into the top cover design to allow for efficient management of battery cell venting events. When a battery cell vents, the gas is guided through a vent into the first hollow section. This controlled path helps isolate hot gases from sensitive components and other battery array elements.

[0126] The separate second hollow section formed by the second and third walls provides a protected space for the electrical components. This separation ensures that these components are not exposed to the hot gases flowing through the first hollow section.

[0127] By combining these components, the top cover design establishes a comprehensive system for managing gas flow and thermal events within the battery pack.

[0128] Any features of the examples or embodiments outlined above can be combined to create additional examples or embodiments without losing the intended effect. It should be understood that the descriptions of the embodiments or examples provided above are merely exemplary, and various modifications can be made by those skilled in the art. Furthermore, those skilled in the art will recognize that many further modifications and combinations of the aspects are possible. Therefore, the described aspects are intended to cover all such changes, modifications, and variations that fall within the scope of the appended claims.

Claims

1. A top cover for a battery pack, the top cover being configured to attach to a battery pack comprising a plurality of battery arrays and substantially forming a top cover for the battery arrays within the battery pack, wherein: The top cover includes a first wall, a second wall, and a third wall; The first wall and the second wall are spaced apart from each other to form a first hollow portion, and the second wall and the third wall are spaced apart from each other to form a second hollow portion; The first wall forms at least a portion of the top cover of each of the plurality of battery arrays; The top cover includes at least one vent inlet and at least one vent outlet, the at least one vent outlet opening to the atmosphere, such that the first hollow portion provides a fluid flow path between the at least one vent inlet and the at least one vent outlet; and The second hollow portion is not in fluid communication with the first hollow portion.

2. The top cover according to claim 1, wherein, The at least one ventilation inlet passes through the second wall.

3. The top cover according to claim 1 or claim 2, wherein, The shape of the second wall divides the first hollow portion into multiple chambers.

4. The top cover according to claim 3, wherein, The plurality of chambers in the first hollow portion are not in fluid communication with each other.

5. The top cover according to claim 3 or claim 4, wherein, Each chamber is basically aligned with the battery array.

6. The top cover according to claim 5, wherein, Each corresponding battery array is in fluid communication with a corresponding chamber of the top cover.

7. The top cover according to claim 6, wherein, Each battery array includes a separate vent to the corresponding chamber of the top cover.

8. The top cover according to any one of the preceding claims, wherein, The second hollow portion is configured to accommodate busbars or wiring.

9. The top cover according to any one of the preceding claims, wherein, Each of the at least one ventilation inlet includes a bursting zone.

10. The top cover according to claim 9, wherein, Each burst area includes the fragile part.

11. The top cover according to claim 10, wherein, The fragile portion is configured to fracture at a predetermined pressure level.

12. The top cover according to any one of the preceding claims, wherein, The at least one ventilation inlet includes a one-way valve.

13. The top cover according to any one of the preceding claims, wherein, The opposing surfaces of the second and third walls are coated with silicate minerals.

14. A battery pack comprising a top cover according to any one of claims 1-13 and at least one battery array.

15. A vehicle comprising the battery pack according to claim 14.

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