Expansion chamber for a battery system

Abstract

A battery pack comprising a battery cell holder having one or more slots, one or more battery cells disposed in the battery cell holder, a thermal barrier layer coupled to the battery cell holder and covering the one or more battery cells and the one or more slots, a first chamber adjacent to the thermal barrier layer and coupled to the battery cell holder, the first chamber comprising one or more first outlets; and a second chamber corresponding to the first chamber and coupled to the battery cell holder, the second chamber comprising one or more second outlets spaced apart from the first outlets of the first chamber.

Description

Technical Field

[0001] This disclosure relates generally to battery systems, and more specifically to heat dissipation systems for battery modules and battery packs. Background Technology

[0002] Battery systems are widely used in a variety of applications, including electric vehicles, portable electronic devices, and energy storage systems. These systems typically include mechanisms to help manage heat propagation events. Various systems and methods have been developed to address the challenges associated with heat propagation scenarios. The shortcomings of existing systems and methods are addressed through one or more aspects of this disclosure. Summary of the Invention

[0003] In one configuration, a battery pack is provided, the battery pack including a battery cell holder having one or more slots, one or more battery cells disposed in the battery cell holder, a thermal barrier layer coupled to the battery cell holder and covering the one or more battery cells and the one or more slots, a first chamber adjacent to the thermal barrier layer and coupled to the battery cell holder, and a second chamber corresponding to the first chamber and coupled to the battery cell holder, the first chamber including one or more first outlets, and the second chamber including one or more second outlets spaced apart from the first outlets of the first chamber.

[0004] The battery pack may include one or more of the following optional aspects. For example, the battery pack may include a first fluid conduit disposed between a first chamber and a thermal barrier. The first fluid conduit may extend between one or more slots and one or more first outlets of the first chamber. The battery pack may include a second fluid conduit disposed between a first chamber and a second chamber. The second fluid conduit may extend between one or more first outlets of the first chamber and one or more second outlets of the second chamber.

[0005] According to at least one aspect, a first chamber includes a first serpentine channel, and a second chamber may include a second serpentine channel corresponding to the first serpentine channel. The first chamber may include a first serpentine path extending along the first serpentine channel and from one or more battery cells to one or more first outlets of the first chamber. The second chamber may include a second serpentine path extending along the second serpentine channel and from one or more first outlets of the first chamber to one or more second outlets of the second chamber. The second serpentine channel may include staggered fins extending toward the first chamber into the second serpentine path. The second serpentine channel may include ribs extending toward the first chamber into the second serpentine path.

[0006] In another configuration, a vehicle is provided, comprising a body extending between a first end and a second end, an electric motor coupled to the body, and a battery pack coupled to the body and communicatively coupled to the electric motor. The battery pack includes a battery cell holder having one or more slots, one or more battery cells disposed in the one or more slots, a thermal barrier layer coupled to the battery cell holder and covering the one or more battery cells and the one or more slots, a first chamber adjacent to the thermal barrier layer and coupled to the battery cell holder, and a second chamber corresponding to the first chamber and coupled to the battery cell holder, the first chamber including one or more first outlets, and the second chamber including one or more second outlets spaced apart from the first outlets of the first chamber.

[0007] The vehicle may include one or more of the following optional aspects. For example, the battery pack may include a first fluid conduit disposed between a first chamber and a thermal barrier. The first fluid conduit may extend between one or more slots and one or more first outlets of the first chamber. The battery pack may include a second fluid conduit disposed between a first chamber and a second chamber. The second fluid conduit may extend between one or more first openings of the second chamber and one or more second outlets.

[0008] According to at least one aspect, a first chamber may include a first serpentine channel, and a second chamber may include a second serpentine channel corresponding to the first serpentine channel. The first chamber may include a first serpentine path along the first serpentine channel and may extend from one or more battery cells to one or more first outlets of the first chamber. The second chamber may include a second serpentine path along the second serpentine channel and may extend from one or more first outlets of the first chamber to one or more second outlets of the second chamber. The second serpentine channel may include staggered fins extending toward the first chamber into the second serpentine path. The second serpentine channel may include ribs extending toward the first chamber into the second serpentine path. Attached Figure Description

[0009] 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.

[0010] Figure 1 It is a front perspective view of a vehicle based on the principles of this disclosure;

[0011] Figure 2 This is a partial exploded view of a battery pack with an expansion chamber;

[0012] Figure 3A yes Figure 2 A partial sectional view of the expansion chamber;

[0013] Figure 3B yes Figure 3AA bottom view of a channel in one configuration of the external chamber of the expansion chamber;

[0014] Figure 3C yes Figure 3A A bottom view of the passageway of another configuration of the outer chamber of the expansion chamber;

[0015] Figure 4A This is a partial exploded view of a battery pack with an expansion chamber;

[0016] Figure 4B yes Figure 4A A cross-sectional view of the battery pack;

[0017] Figure 5A This is a top-down exploded view of a battery pack with an expansion chamber; and

[0018] Figure 5B yes Figure 5A A partial exploded view of the bottom of the battery pack.

[0019] Throughout the accompanying drawings, corresponding reference numerals indicate the relevant parts. Detailed Implementation

[0020] The exemplary configuration will now be described more fully with reference to the accompanying drawings. Exemplary configurations are 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 configurations of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that the exemplary configurations may be implemented in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0021] The terminology used herein is for the purpose of describing particular exemplary configurations 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,” “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.

[0022] 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.

[0023] 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.

[0024] In this application, including the following definitions, the term "module" may be replaced by the term "circuit". The term "module" may refer to, be a 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.

[0025] 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 the 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.

[0026] 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.

[0027] 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.

[0028] 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 bootloaders). 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.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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 web page to a web browser on the user's client device in response to a request received from a web browser.

[0033] Electric vehicles may be equipped with battery packs comprising one or more battery cells. Lithium-ion batteries are commonly used in vehicles due to their high energy density and power density. However, sometimes a series of uncontrolled exothermic reactions (i.e., heat propagation) can occur within lithium-ion batteries. These reactions can cause the internal temperature of the battery to rise, leading to instability and degradation of the battery's internal structure, and ultimately resulting in battery failure and / or vehicle damage. Managing the flow of gaseous and particulate matter from one or more unstable battery cells is desirable to mitigate damage to adjacent battery cells and / or the vehicle in which the cells are located.

[0034] As described in more detail below, a rechargeable energy storage system (RESS) or battery module may be equipped with an expansion chamber that allows gases and particulate matter generated during a thermal propagation event to expand and cool. The expansion chamber may include a dual-chamber design that defines a path that allows gases and / or particulate matter to dissipate and cool before leaving the expansion chamber.

[0035] refer to Figure 1 This provides an illustrative example of a vehicle 10. The vehicle 10 has a body 12 extending between a first end 14 and a second end 16. The vehicle 10 includes a battery pack 18 coupled to the body 12. The battery pack 18 includes one or more battery cells communicatively coupled to each other. In this illustrative example, the battery cells may be cylindrical battery cells, prismatic battery cells, or another cell design used in the automotive industry. The battery pack 18 is communicatively coupled to an electric motor 22, which is coupled to the body 12 via a cable 24.

[0036] refer to Figure 2An illustrative example of a battery pack 100 having a cell holder 102 and an expansion chamber 104 is provided. The cell holder 102 includes a first side 106 and a second side 108 spaced apart from the first side 106. The cell holder 102 has a peripheral wall 110 extending between the first side 106 and the second side 108 and includes one or more mounting flanges 112 configured to facilitate coupling or otherwise attaching the battery pack 100 to a vehicle (e.g., vehicle 10). For example, the mounting flange 112 may have an opening 114 configured to receive a fastener (not shown). The cell holder 102 may be configured to receive one or more battery modules (not shown) and / or one or more battery cells 116. For example, the battery cell holder 102 may include a potting structure (e.g., a cellular holder) having one or more slots 118 extending between a first side 106 and a second side 108 and configured to receive one or more battery cells 116. In this example, the battery cell 116 is a cylindrical battery cell; however, the principles of this disclosure are equally applicable to battery cells having another shape (e.g., a prismatic battery cell). According to one aspect, the slots 118 may be arranged such that the battery cells 116 are positioned in rows or columns corresponding to the expansion chamber 104. The battery cells 116 are communicatively connected to each other using busbars (not shown) or another method used in the automotive industry.

[0037] Continue to refer to Figure 2 One or more alignment pins 120 are coupled to the battery cell holder 102 and extend away from the first side 106. The one or more alignment pins 120 are configured to receive and position the expansion chamber 104 relative to the battery cell holder 102. The battery cell holder 102 also includes one or more holes 122 configured to receive one or more fasteners 124 for securing the expansion chamber 104 to the battery cell holder 102.

[0038] The expansion chamber 104 includes a thermal barrier layer 130, a first or internal chamber 132, and a second or external chamber 134. (See reference) Figure 2 and Figure 3A The thermal barrier layer 130 is coupled to the battery cell holder 102. More specifically, the thermal barrier layer 130 includes a bottom side 136, which is coupled to or otherwise attached to a first side 106 of the battery cell holder 102 and covers one or more slots 118. The thermal barrier layer 130 includes a top side 138, which is disposed on a side opposite to the bottom side 136 and remote from the first side 106 of the battery cell holder 102.

[0039] The thermal barrier layer 130 includes one or more fastener through-holes 140 arranged adjacent to a periphery 142 of the thermal barrier layer 130. The fastener through-holes 140 are configured to correspond to one or more alignment pins 120 and are desirable for positioning the thermal barrier layer 130 relative to the battery cell retainer 102. At least some of the fastener through-holes 140 correspond to holes 122 in the battery cell retainer 102 and are configured to receive fasteners 124 for securing the thermal barrier layer 130 to the battery cell retainer 102. According to one aspect, the thermal barrier layer 130 may be formed of a mica material or another insulating material used in the automotive industry. Optionally, the thermal barrier layer 130 may have a perforation 144 extending between a bottom side 136 and a top side 138 and arranged to correspond to the shape of the battery cell 116 and / or slot 118. The perforation 144 can be configured to allow a portion of the thermal barrier layer 130 corresponding to one or more battery cells 116 undergoing heat transfer to be easily separated, allowing gaseous and particulate matter to flow through the thermal barrier layer 130 and into, for example, the internal chamber 132. The perforation 144 ensures that the area surrounding the thermal barrier layer 130 remains undisturbed, allowing the thermal barrier layer 130 to operate to protect adjacent battery cells 116 from the gaseous and particulate matter leaving the one or more battery cells 116 undergoing heat transfer.

[0040] An internal chamber 132 is coupled to a battery cell holder 102, and more specifically, to a first side 106 of the battery cell holder 102 and a thermal barrier layer 130. The internal chamber 132 includes a first side 150 and a second side 152 disposed on a side opposite to the first side 150. The first side 150 contacts and faces the top side 138 of the thermal barrier layer 130. The internal chamber 132 includes one or more fastener through-holes 154 arranged adjacent to the periphery 156 of the internal chamber 132. The fastener through-holes 154 are configured to correspond to one or more alignment pins 120 and are desirable for positioning the internal chamber 132 relative to the battery cell holder 102 and the thermal barrier layer 130. At least some of the fastener through-holes 154 correspond to holes 122 in the battery cell holder 102 and are configured to receive fasteners 124 for securing the internal chamber 132 to the battery cell holder 102. According to one aspect, the internal chamber 132 includes one or more first outlets 158 extending through a first side 150 and a second side 152. The first outlets 158 are configured to allow gaseous and particulate matter to escape from a first fluid conduit 160 disposed between the top side 138 of the thermal barrier layer 130 and the first side 150 of the internal chamber 132. According to one aspect, the internal chamber 132 may be formed (e.g., stamped) to include a first serpentine channel 162. In doing so, the first fluid conduit 160 includes a first serpentine path 164 between the battery cell 116 and / or slot 118 and one or more first outlets 158. The first serpentine channel 162 guides gaseous and particulate matter along the first serpentine path 164 and allows the internal chamber 132 to function as a radiator to remove heat from the gaseous and particulate matter. Figure 3A As shown, portions of the first serpentine channel 162 are arranged between rows of battery cells 116, and therefore, the first serpentine channel 162 does not obstruct the flow of gas and particulate matter into and along the first serpentine path 164. In some embodiments, the internal chamber 132, or at least a portion thereof, is formed of a non-ferrous metal material. For example, this may be desirable to reduce the weight of the expansion chamber 104.

[0041] Continue to refer to Figure 2 and Figure 3AThe outer chamber 134 is coupled to the battery cell holder 102. More specifically, the outer chamber 134 includes a first side 170 that faces and contacts a second side 152 of the inner chamber 132. The outer chamber 134 has a second side 172 disposed on a side opposite to the first side 170. The outer chamber 134 includes one or more fastener through holes 174 arranged adjacent to a periphery 176 of the outer chamber 134. The fastener through holes 174 are configured to correspond to one or more alignment pins 120 and are desirable for positioning the outer chamber 134 relative to the inner chamber 132. At least some of the fastener through holes 174 of the outer chamber 134 correspond to the holes 122 of the battery cell holder 102, the fastener through holes 140 of the thermal barrier layer 130, and the fastener through holes 154 of the inner chamber 132. When the fastener 124 is inserted through the fastener through holes 140, 154, 174 and secured within the hole 122 of the battery cell holder 102, a seal is formed adjacent to and along the peripheries 142, 156, 176. For example, the seals formed between the battery cell holder 102 and the expansion chamber 104, and between the thermal barrier layer 130, the inner chamber 132, and the outer chamber 134, prevent premature escape of gases and particulate matter from the expansion chamber 104 during a thermal propagation event. According to one aspect, the outer chamber 134 includes one or more second outlets 178 extending through the first side 170 and the second side 172. The second outlets 178 are configured to allow gases and particulate matter to escape from a second fluid conduit 180 disposed between the second side 152 of the inner chamber 132 and the first side 170 of the outer chamber 134. According to one aspect, the outer chamber 134 may be formed (e.g., stamped) to include a second serpentine channel 182 that substantially corresponds to the shape of the first serpentine channel 162. In doing so, the second fluid conduit 180 includes a second serpentine path 184 between the first outlet 158 ​​of the inner chamber 132 and the second outlet 178 of the outer chamber 134. The second serpentine path 182 guides gas and particulate matter along the second serpentine path 184 and allows the outer chamber 134 to function as a radiator to remove heat from the gas and particulate matter. In some embodiments, the outer chamber 134 may be formed of a material with high thermal conductivity, such as an aluminum alloy or a copper alloy.

[0042] refer to Figure 3B and Figure 3C A portion of the first serpentine channel 162 or the second serpentine channel 182 provides a thermal interface for removing heat from gaseous and particulate matter exiting one of the battery cells 116. In at least some embodiments, a portion of the first serpentine channel 162 and / or a portion of the second serpentine channel 182 may include one or more protrusions 190, which increase the surface area to enhance heat dissipation. (See also...) Figure 3BThe first serpentine channel 162 and / or the second serpentine channel 182 may include one or more fins 192 that may be formed (i.e., stamped) or otherwise arranged in the channels 162, 182. The fins 192 may be staggered along the channels 162, 182, such as... Figure 3C As shown. Interlacing the fins 192 increases turbulence within channels 162 and 182, and thus improves heat transfer to the inner chamber 132 and / or the outer chamber 134. (Refer to...) Figure 3B The first serpentine channel 162 and / or the second serpentine channel 182 may include one or more ribs 194, which may be formed (i.e., stamped) or otherwise arranged in the channels 162, 182.

[0043] Figures 4A to 4B Another exemplary configuration of the battery pack 200 is shown. This configuration is similar in many respects to... Figure 1 and Figure 2-3C The configuration. Therefore, the descriptions of the configurations are incorporated into each other, and it is generally not necessary to repeat descriptions of common topics in the configurations.

[0044] refer to Figure 4A An illustrative example of a battery pack 200 having a battery cell holder 202 and an expansion chamber 204 is provided. The battery cell holder 202 includes a first side 206 and a second side 208 spaced apart from the first side 206. The battery cell holder 202 has a peripheral wall 210 extending between the first side 206 and the second side 208 and includes one or more mounting flanges 212 configured to facilitate coupling or otherwise attaching the battery pack 200 to a vehicle (e.g., vehicle 10). For example, the mounting flange 212 may have an opening 214 configured to receive a fastener (not shown). The battery cell holder 202 may be configured to receive one or more battery modules (not shown) and / or one or more battery cells 216. For example, the battery cell holder 202 may include a potting structure (e.g., a cellular holder) having one or more slots 218 extending between the first side 206 and the second side 208 and configured to receive one or more battery cells 216. In this example, battery cell 216 is a cylindrical battery cell; however, the principles of this disclosure are equally applicable to battery cells having another shape (e.g., prismatic battery cells). According to one aspect, slot 218 can be arranged such that battery cells 216 are positioned in rows or columns corresponding to expansion chambers 204. Battery cells 216 are communicatively connected to each other using busbars (not shown) or another method used in the automotive industry.

[0045] Continue to refer to Figure 4AOne or more alignment pins 220 are coupled to the battery cell holder 202 and extend away from the first side 206. The one or more alignment pins 220 are configured to receive and position the expansion chamber 204 relative to the battery cell holder 202. The battery cell holder 202 also includes one or more holes 222 configured to receive one or more fasteners 224 for securing the expansion chamber 204 to the battery cell holder 202.

[0046] The expansion chamber 204 includes a thermal barrier layer 230, a thermal barrier plate 232, a first or internal chamber 234, and a second or external chamber 236. (See reference) Figure 4A and Figure 4B The thermal barrier layer 230 is coupled to the battery cell holder 202. More specifically, the thermal barrier layer 230 includes a bottom side 238 coupled to or otherwise attached to a first side 206 of the battery cell holder 202 and covering one or more slots 218. The thermal barrier layer 230 includes a top side 240 disposed on the side opposite to the bottom side 238 and away from the first side 206 of the battery cell holder 202. According to one aspect, the thermal barrier layer 230 may be formed of a mica material or another insulating material used in the automotive industry.

[0047] Continue to refer to Figure 4A and Figure 4B A thermal barrier 232 is coupled to the battery cell holder 202 and sandwiches the thermal barrier layer 230 between the lower side 242 and the battery cell holder 202. The lower side 242 faces and contacts the first side 206 of the battery cell holder 202 and the top side 240 of the thermal barrier layer 230. The thermal barrier 232 includes an upper side 244 disposed on the side opposite to the lower side 242 and facing away from the first side 206 of the battery cell holder 202. The thermal barrier 232 extends between a first end 246 and a second end 248 spaced apart from the first end 246 relative to the longitudinal direction 250, and extends between a first side 252 and a second side 254 spaced apart from the first side 252 relative to the lateral direction 256. The thermal barrier 232 includes one or more fastener through holes 258 arranged adjacent to the periphery 260 of the thermal barrier 232. Fastener through holes 258 are configured to correspond to one or more alignment pins 220 and are desirable for positioning the thermal barrier plate 232 relative to the battery cell holder 202 and the thermal barrier layer 230. At least some of the fastener through holes 258 correspond to holes 222 in the battery cell holder 202 and are configured to receive fasteners 224 for securing the thermal barrier plate 232 to the battery cell holder 202.

[0048] refer to Figure 4AThe thermal baffle 232 includes one or more openings 262 extending through the lower side 242 and the upper side 244 and corresponding to one or more slots 218. The thermal baffle 232 further includes a flow guide 264 coupled to and extending away from the upper side 244. The flow guide 264 includes a central ridge 266 and one or more partitions 268 configured to guide the flow of gas and particulate matter within the expansion chamber 204. The central ridge 266 is coupled to the upper side 244 and divides the thermal baffle 232 into a first flow region 270 and a second flow region 272 relative to a lateral direction 256. According to one aspect, the central ridge 266 may include one or more peaks 274 and one or more valleys 276 configured to induce turbulence within the expansion chamber 204. The central ridge 266, and more specifically, the peaks 274 and valleys 276, also provide support for a portion of the internal chamber 234. One or more partitions 268 are coupled to the upper side 244 and extend transversely to the central ridge 266 between the first side 252 and the second side 254 of the thermal baffle 232. The central ridge 266 and the partitions 268 define one or more compartments 278 within the first flow region 270 and the second flow region 272. For example, during a heat propagation event, the compartments 278 may be desirable to interrupt flow and / or enhance cooling of gaseous and particulate matter.

[0049] An internal chamber 234 is coupled to an upper side 244 of a thermal baffle 232. The internal chamber 234 includes a lower side 280 and an upper side 282 disposed on the side opposite to the lower side 280. The lower side 280 contacts and faces the upper side 244 of the thermal baffle 232. The internal chamber 234 includes one or more fastener through-holes 284 arranged adjacent to a periphery 286 of the internal chamber 234. The fastener through-holes 284 are configured to correspond to one or more alignment pins 220 and are desirable for positioning the internal chamber 234 relative to the battery cell holder 202 and the thermal baffle 232. At least some of the fastener through-holes 284 correspond to holes 222 in the battery cell holder 202 and are configured to receive fasteners 224 for securing the internal chamber 234 to the battery cell holder 202.

[0050] refer to Figure 4A and Figure 4BThe lower side 280 includes a first cavity 288 corresponding to the thermal baffle 232 and defining a first fluid conduit 290. Optionally, the first cavity 288 may be formed (e.g., stamped) with corrugated sidewalls 292 corresponding to one or more compartments 278 of the thermal baffle 232. The corrugated sidewalls 292 are desirable for increasing turbulence within the first fluid conduit 290 and enhancing cooling of gaseous and particulate matter during heat propagation events. According to another aspect, the first cavity 288 may be formed with a recess 294 extending along and engaging the central ridge 266. In other words, the recess 294 further defines a first flow region 270 and a second flow region 272 within the first fluid conduit 290. The internal chamber 234 and more specifically the first cavity 288 include one or more outlets extending through the lower side 280 and the upper side 282. In this illustrative configuration, gaseous and particulate matter originating from battery cells 216 arranged adjacent to the first flow region 270 can flow into and out of one or more compartments 278 and exit through one or more of the first outlets 296. Similarly, gaseous and particulate matter originating from battery cells 216 arranged adjacent to the second flow region 272 can flow into and out of one or more compartments 278 and exit through one or more of the second outlets 298.

[0051] Continue to refer to Figure 4A and 4B An outer chamber 236 is coupled to the upper side 282 of an inner chamber 234. The outer chamber 236 includes a lower side 300 and an upper side 302 disposed on the side opposite to the lower side 300. The lower side 300 contacts and faces the upper side 282 of the inner chamber 234. The outer chamber 236 includes one or more fastener through-holes 304 arranged adjacent to its periphery 306. The fastener through-holes 304 are configured to correspond to one or more alignment pins 220 and are desirable for positioning the outer chamber 236 relative to the battery cell holder 202, the thermal baffle 232, and the inner chamber 234. At least some of the fastener through-holes 304 correspond to holes 222 in the battery cell holder 202 and are configured to receive fasteners 224 for securing the outer chamber 236 to the battery cell holder 202.

[0052] The lower side 300 of the outer chamber 236 includes a second cavity 308 corresponding to the inner chamber 234 and defining a second fluid conduit 310. Optionally, the second cavity 308 may be formed (e.g., stamped) with a corrugated sidewall 312 corresponding to the corrugated sidewall 292 of the first cavity 288 of the inner chamber 234. According to another aspect, the second cavity 308 may be formed with one or more recesses 314 extending transversely to the recesses 294 of the first cavity 288 and extending into the second cavity 308. In some embodiments, one or more recesses 314 may engage the upper side 282 of the inner chamber 234. The one or more recesses 314 of the second cavity 308 interrupt the flow pattern of gas and particulate matter within the second fluid conduit 310 during a heat propagation event and provide a thermal interface for engaging gas and particulate matter. The outer chamber 236, and more specifically the second chamber 308, includes one or more outlets 316 extending through the lower side 300 and the upper side 302. A second fluid conduit 310 extends between the first outlet 296 and the second outlet 298 of the inner chamber 234 and one or more outlets 316 of the outer chamber 236.

[0053] Figure 5A and Figure 5B Another exemplary configuration of the battery pack 400 is shown. This configuration is similar in many ways to... Figure 1 , Figures 2 to 3C and Figures 4A to 4B The configuration. Therefore, the descriptions of the configurations are incorporated into each other, and it is generally not necessary to repeat descriptions of common topics in the configurations.

[0054] refer to Figure 5A and 5BAn illustrative example of a battery pack 400 having a battery cell holder 402 and an expansion chamber 404 is provided. The battery cell holder 402 includes a first side 406 and a second side 408 spaced apart from the first side 406. The battery cell holder 402 has a peripheral wall 410 extending between the first side 406 and the second side 408 and includes one or more mounting flanges 412 configured to facilitate coupling or otherwise attaching the battery pack 400 to a vehicle (e.g., vehicle 10). For example, the mounting flange 412 may have an opening 414 configured to receive a fastener (not shown). The battery cell holder 402 may be configured to receive one or more battery modules (not shown) and / or one or more battery cells 416. For example, the battery cell holder 402 may include a potting structure (e.g., a cellular holder) having one or more slots 418 extending between the first side 406 and the second side 408 and configured to receive one or more battery cells 416. In this example, battery cell 416 is a cylindrical battery cell; however, the principles of this disclosure are equally applicable to battery cells having another shape (e.g., prismatic battery cells). Battery cell holder 402 includes one or more holes 420 configured to receive one or more fasteners 422 for securing expansion chamber 404 to battery cell holder 402.

[0055] Expansion chamber 404 includes a thermal barrier layer 430, a first or internal chamber 432, and a second or external chamber 434. (Reference) Figure 5A and 5B The thermal barrier layer 430 is coupled to the battery cell holder 402. More specifically, the thermal barrier layer 430 includes a bottom side 436, which is coupled to or otherwise attached to a first side 406 of the battery cell holder 402 and covers one or more slots 418. The thermal barrier layer 430 includes a top side 438, which is disposed on the side opposite to the bottom side 436 and away from the first side 406 of the battery cell holder 402.

[0056] An internal chamber 432 is coupled to a first side 406 of a battery cell holder 402. The internal chamber 432 includes a first side 450 and a second side 452 disposed on a side opposite to the first side 450. The internal chamber 432 includes one or more fastener through-holes 454 arranged adjacent to its periphery 456. At least some of the fastener through-holes 454 correspond to holes 420 in the battery cell holder 402 and are configured to receive fasteners 422 for securing the internal chamber 432 to the battery cell holder 402.

[0057] The first side 450 includes a first cavity 458 corresponding to a thermal barrier layer 430 and defining a first fluid conduit 460. The first cavity 458 includes a first end 462 and a second end 464 spaced apart from the first end 462, and a sidewall 466 extending from the first end 462 to the second end 464. The first end 462 includes one or more first outlets 468, and the second end 464 includes one or more second outlets 470. The first outlets 468 and the second outlets 470 are configured to allow gaseous and particulate matter to escape from the first fluid conduit 460.

[0058] The first cavity 458 may further include one or more first recesses 472 that extend into the first fluid conduit 460 and engage with the top side 438 of the thermal barrier layer 430. The first recesses 472 may be arranged in a pattern (e.g., rows) or dispersedly. The first recesses 472 are desirable for increasing turbulence within the first fluid conduit 460 and enhancing the cooling of gaseous and particulate matter during heat propagation events.

[0059] An outer chamber 434 is connected to a second side 452 of an inner chamber 432 and a battery cell holder 402. The outer chamber 434 includes a first side 480 and a second side 482 disposed on a side opposite to the first side 480. The first side 480 contacts and faces the second side 452 of the inner chamber 432. The outer chamber 434 includes one or more fastener through-holes 484 arranged adjacent to a periphery 486 of the outer chamber 434. At least some of the fastener through-holes 484 correspond to holes 420 in the battery cell holder 402 and are configured to receive fasteners 422 for securing the outer chamber 434 to the battery cell holder 402.

[0060] The first side 480 includes a second cavity 488 corresponding to the first cavity 458 of the internal chamber 432 and defining a second fluid conduit 490. The second cavity 488 includes a first end 492 and a second end 494 spaced apart from the first end 492, and a sidewall 496 extending from the first end 492 to the second end 494. The sidewall 496 includes one or more outlets 498 configured to allow gaseous and particulate matter to escape from the second fluid conduit 490.

[0061] The second cavity 488 may also include one or more first recesses 500 and one or more second recesses 502, each extending into the first fluid conduit 460. The first recesses 500 are configured to correspond to a first recess 472 of the first cavity, and the second recesses are configured to engage a second side 482 of the internal chamber 432. The first recesses 500 and second recesses 502 of the second cavity 488 may be desirable for increasing turbulence within the second fluid conduit 490 and enhancing cooling of gaseous and particulate matter during heat propagation events.

[0062] 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.

[0063] 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.

[0064] 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.

Claims

1. A battery pack, comprising: A battery cell holder having one or more slots; One or more battery cells are arranged in a battery cell holder; A thermal barrier layer is attached to the battery cell holder and covers the one or more battery cells and the one or more slots; A first chamber, adjacent to the thermal barrier layer and connected to the battery cell holder, the first chamber includes one or more first outlets; and A second chamber, corresponding to the first chamber and coupled to the battery cell holder, includes one or more second outlets spaced apart from the first outlet of the first chamber.

2. The battery pack according to claim 1, wherein, The battery pack includes a first fluid conduit disposed between the first chamber and the thermal barrier layer.

3. The battery pack according to claim 2, wherein, The first fluid conduit extends between the one or more slots and the one or more first outlets of the first chamber.

4. The battery pack according to claim 3, wherein, The battery pack includes a second fluid conduit disposed between the first chamber and the second chamber.

5. The battery pack according to claim 4, wherein, The second fluid conduit extends between one or more first outlets of the first chamber and one or more second outlets of the second chamber.

6. The battery pack according to claim 1, wherein, The first chamber includes a first serpentine channel, and the second chamber includes a second serpentine channel corresponding to the first serpentine channel.

7. The battery pack according to claim 6, wherein, The first chamber includes a first serpentine path that runs along the first serpentine channel and extends from the one or more battery cells to the one or more first outlets of the first chamber.

8. The battery pack according to claim 7, wherein, The second chamber includes a second serpentine path that runs along the second serpentine channel and extends from the one or more first outlets of the first chamber to the one or more second outlets of the second chamber.

9. The battery pack according to claim 8, wherein, The second serpentine channel includes staggered fins extending into the second serpentine path.

10. The battery pack according to claim 8, wherein, The second serpentine channel includes ribs extending into the second serpentine path.

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