Multifunctional carrier with integrated structural, cooling and transverse elastic compliance functions for use with electric vehicle battery packs

Abstract

This disclosure describes a multifunctional, integrated supersupport assembly structure with integrated structural, cooling, and transverse elastic compliance functions and thermal management propagation protection (TMP protection). The supersupport assembly comprises a pair of parallel faceplates, coolant channel cover plates, and coolant channels defined by the faceplate and one or more coolant channel cover plates. The structural design of the coolant channels, and the corresponding air gaps formed between them, allows the transverse elastic compliance of the supersupport assembly to be tuned to different degrees of elasticity. Top, bottom, and / or end structural channels may be included.A pair of TMP suppression channels can be attached to the supercarrier assembly structure with an adhesive “thermal fuse” which preferably melts and causes the pair of TMP suppression channels to detach from the supercarrier assembly during overheating in a TMP event.

Description

Introduction

[0001] The present disclosure relates to structural support beams and thermal cooling plates for use with rechargeable battery packs in electric vehicles. More specifically, aspects of this disclosure relate to multifunctional, integrated structural beams with internal coolant channels and tunable transverse elastic compliance that also provide protection against thermal management propagation (TMP) events.

[0002] In the design of rechargeable energy storage systems (RESS), discrete, individual components are used to achieve different functions within the battery pack. For example, some thick and rigid cross members are used for structural integrity. Separate cold plates are used to maintain the temperature of the battery cells. Finally, aerogels or other elastic (compliant) materials are used to facilitate transverse pre-compression and allow transverse expansion of the battery cells during charge and recharge cycles. These individual components take up valuable space within the battery pack, resulting in a reduction in the overall energy density of the battery pack. Thermal management propagation (TMP)Thermal management propagation refers to a situation in which the temperature of one battery cell rises rapidly, causing the temperature of a neighboring battery cell to also rise rapidly. Description

[0003] A “superbeam” assembly, as considered here, provides an integrated solution that combines structural support beams with internal coolant channels and tunable transverse elastic compliance in a single, integrated multifunctional structure, including protection against TMP events.

[0004] In one or more embodiments, the superbeam assembly comprises a pair of parallel faceplates, one or more coolant channel cover plates, and one or more coolant channels defined by the faceplate and the one or more coolant channel cover plates. The structural design of the coolant channels, and the corresponding air gaps formed therebetween, allows the transverse elastic compliance of the superbeam assembly to be tuned to varying degrees of elasticity. Optional top, bottom, and / or end structural channels provide enhanced load-bearing capacity.

[0005] In one example, a pair of TMP suppression channels may be attached to the supercarrier assembly structure with an adhesive "thermal fuse" that preferably melts and causes the pair of TMP suppression channels to detach from the supercarrier assembly during overheating in a TMP event.

[0006] The multifunctional supercarrier assembly may further include: a left coolant inlet located at a proximal end of the left front plate; a left coolant outlet located at a distal end of the left front plate; a right coolant inlet located at a proximal end of the right front plate; and a right coolant outlet located at a distal end of the right front plate. The left coolant channel may have a C-shaped cross-section, and the right coolant channel may have a C-shaped cross-section.

[0007] In one example, the multifunction supercarrier assembly may include a left battery cell disposed adjacent to the left front panel and a right battery cell disposed adjacent to the right front panel. In another embodiment, a left thermal interface material (TIM) may be disposed between the left battery cell and the left front panel; and a right TIM material may be disposed between the right battery cell and the right front panel.

[0008] The superbeam assembly may further include an upper structural channel attached to the left front panel and the right front panel. The upper structural channel may be attached to an upper left extension of the left front panel and to an upper right extension of the right front panel. The upper structural channel may have a T-shaped or M-shaped cross-section.

[0009] In one example, the multi-function supercarrier assembly may further comprise: an upper left flange integrally connected to the left front panel; and an upper right flange integrally connected to the right front panel; wherein the upper structural channel is connected to the upper left flange and the upper right flange. The upper structural channel may be adhesively connected to the upper left flange with a left adhesive strip; and to the upper right flange with a right adhesive strip.

[0010] In another embodiment, the multi-function supercarrier assembly may further include a lower structural channel connected to the left front panel; and the lower structural channel connected to the right front panel. The lower structural channel may have an I-shaped cross-section. In another example, a lower left portion of the left front panel may have a zigzag-shaped cross-section; and a lower right portion of the right front panel may have a zigzag-shaped cross-section.

[0011] In one example, the multifunction supercarrier assembly further includes: an upper air gap disposed between the left front panel and the right front panel; and a lower air gap disposed between the left front panel and the right front panel.

[0012] In one or more embodiments, the upper structural channel and the lower structural channel may have a width that is less than or equal to the width of a battery cell.

[0013] In one example, a supercarrier assembly further includes an upper thermal management propagation suppression (TMP) duct attached to an upper portion of the supercarrier assembly; and a lower TMP suppression duct attached to a lower portion of the supercarrier assembly.

[0014] The supercarrier assembly may further include: a left upper flange integrally connected to the left front panel; a right upper flange integrally connected to the right front panel; a left lower flange integrally connected to the left front panel; a right lower flange integrally connected to the right front panel; a left upper thermal fuse disposed between the upper TMP suppression channel and the left upper flange; a right upper thermal fuse disposed between the upper TMP suppression channel and the right upper flange; a left lower thermal fuse disposed between the upper TMP suppression channel and the left lower flange; and a right lower thermal fuse disposed between the upper TMP suppression channel and the right lower flange.

[0015] In some embodiments, the upper TMP suppression channel may comprise a plurality of upper Z-bellows segments; and the lower TMP suppression channel may comprise a plurality of lower Z-bellows segments.

[0016] Finally, in one embodiment, an electric vehicle may comprise: an electric vehicle body; a battery pack connected to the electric vehicle body; and a plurality of integrated superbeam assemblies disposed within the battery pack; wherein each superbeam assembly comprises: a left front panel; a right front panel; one or more right coolant channel cover plates; one or more right coolant channel cover plates; one or more left coolant channels defined by the left front panel and by the one or more left coolant channel cover plates; and one or more right coolant channels defined by the right front panel and by the one or more right coolant channel cover plates; and wherein the left front panel is aligned parallel to the left front panel. Brief description of the drawings Fig. Figure 1 shows a schematic perspective view of an example of a battery pack for an electric vehicle with five large structural cross members extending across the width of the battery pack. Fig. 2 shows a schematic perspective view of an example of a battery pack for an electric vehicle having a plurality of multi-function supercarrier assemblies located between pairs of adjacent battery cells, according to the present disclosure. Fig. 3A shows a schematic perspective view of an example half section of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 3B shows a schematic cross-sectional view (end view) (section AA) of an example half section of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 4 shows a schematic cross-sectional view (end view) (section AA) of an example of a complete superbeam assembly with integrated structural, cooling and transverse elastic compliance functions and upper and lower structural channels according to the present disclosure. Fig. 5 shows a schematic cross-sectional view (end view) (section DD) of an example of a complete superbeam assembly with integrated structural, cooling and transverse elastic compliance functions and upper and lower structural channels according to the present disclosure. Fig. 6 shows a schematic cross-sectional view (end view) (section AA) of an example of an upper structural channel according to the present disclosure. Fig. 7 shows a schematic perspective view of an example of one half of a superbeam with integrated structural, cooling and transverse elastic compliance functions and four integral flange sections according to the present disclosure. Fig. 8 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions and two pairs of integral longitudinal flanges attached to each face plate, according to the present disclosure. Fig. 9 shows a schematic exploded perspective view of an example of two half sections of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions, as well as integral circumferential flanges and a top structural channel according to the present disclosure. Fig. 10 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 11 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 12 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 13 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 14 shows a schematic perspective cross-sectional view (side view) (section CC) of an example of a superbeam assembly with integrated structural, cooling and transverse elastic compliance functions as well as upper and lower structural channels and a pair of perpendicular frame housing beams according to the present disclosure. Fig. 15 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling and transverse elastic compliance functions and upper and lower structural channels according to the present disclosure. Fig. 16 shows a schematic cross-sectional view (end view) (section AA) of an example of an upper structural channel according to the present disclosure. Fig. 17 shows a schematic cross-sectional view (end view) (section AA) of an example of a supercarrier assembly faceplate with a pair of vertical extensions according to the present disclosure. Fig. 18 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly faceplate with integral upper and lower peripheral flanges according to the present disclosure. Fig. 19 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly faceplate with integral upper and lower peripheral flanges according to the present disclosure. Fig. 20 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling and transverse elastic compliance functions and upper and lower structural channels according to the present disclosure. Fig. 21 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly with integrated structural, cooling and transverse elastic compliance functions and upper and lower structural channels according to the present disclosure. Fig. 22 shows a schematic top view (section BB) of an example of one half of a superbeam assembly with integrated structural, cooling, and transverse elastic compliance functions and integral circumferential flanges according to the present disclosure. Fig. 23 shows a schematic perspective view of an example of an electric vehicle with an integrated battery pack according to the present disclosure. Fig. 24 shows a schematic perspective view of an example of a complete supercarrier assembly with a full population of adjacent battery cells according to the present disclosure. Fig. 25A shows a schematic side view of an example of a pair of vertical end structure channels attached to the proximal and distal ends of a superbeam assembly according to the present disclosure. Fig. Figure 25B shows a schematic top view (section BB) of an example of a pair of vertical end structure channels attached to the proximal and distal ends of a superbeam assembly according to the present disclosure. Fig. 26 shows a schematic cross-sectional view (section AA) of an example of four supercarrier assemblies with five adjacent battery cells according to the present disclosure. Fig. 27 shows a schematic perspective of an example of seven supercarrier assemblies with thirty-two battery cells arranged in seven parallel rows in a battery pack assembly according to the present disclosure. Fig. 28 shows a schematic cross-sectional view (section AA) of an example of a supercarrier assembly including two battery cells with upper and lower TMP suppression channels, according to the present disclosure. Fig. 29A shows a schematic cross-sectional view (section AA) of an example of an upper TMP suppression channel according to the present disclosure. Fig. 29B shows a schematic cross-sectional view (section AA) of an example of an upper TMP suppression channel with a pair of four Z-bellows segments according to the present disclosure. Fig. 30 shows a schematic perspective cross-sectional view (section A-A) of an example of an upper TMP suppression channel with a series of slots according to the present disclosure. Fig. 31 shows a schematic perspective cross-sectional view (section AA) of an example of an upper TMP suppression channel with a series of multiple perforations according to the present disclosure. Fig. 32 shows a schematic perspective cross-sectional view (section A-A) of an example of an upper TMP suppression channel with a central groove according to the present disclosure. Fig. 33 shows a schematic perspective view of a battery pack frame housing with a single superbeam assembly aligned longitudinally (side to side) along the X direction, according to the present disclosure. Fig. 34 shows a schematic perspective view of a battery pack frame housing with a single superbeam assembly oriented longitudinally (front to back) in the Y direction, according to the present disclosure. Detailed description

[0017] This disclosure includes examples in many different forms. Representative examples of the disclosure are illustrated in the drawings and are described in detail herein, but it is understood that these examples are intended to illustrate the principles disclosed and are not limitations on the general aspects of the disclosure. As such, elements and limitations described, for example, in the "Summary," "Introduction," "Conclusion," and "Detailed Description" sections, but not expressly recited in the claims, should not be incorporated into the claims, individually or in the aggregate, by implication, inference, or otherwise.

[0018] For the purposes of this detailed description, unless expressly excluded: the singular includes the plural and vice versa; the words "and" and "or" apply both in the subjunctive and disjunctive moods; the words "each" and "all" mean "each and all"; and the words "including," "including," "comprising," "with," and the like each mean "including without limitation." Furthermore, words of approximation such as "approximately," "almost," "substantially," "generally," "about," and the like may be used herein to mean "at, near, or almost at," or "within 0-5% of," or "within acceptable manufacturing tolerances," or any logical combination thereof.

[0019] Unless the context indicates otherwise, the term "about" is understood here to mean within a normal range of tolerance, e.g., within 2 standard deviations of the mean. "Approximately" can be understood as within 10%, 5%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. "Approximately" can also be understood to mean the exact value. Unless the context indicates otherwise, the term "approximately" modifies the numerical values ​​stated herein.

[0020] Finally, directional adjectives and adverbs such as forward, aft, inside, outside, starboard, port, vertical, horizontal, upward, downward, ahead, behind, left, right, etc. may be used in relation to a motor vehicle, e.g., a forward direction of travel of a motor vehicle when the vehicle is operated on a horizontal driving surface. The directions 'left' and 'right' are defined by the terms referred to as Section AA in the Fig. 4, 5, 8, 10-13, 15, 20-21 and 28. In Fig. 4 for example, the “left” front panel is position 18 and the “right” front panel is position 18'.

[0021] In some examples, the word “transversal” when referring to “transverse elastic compliance” means that the transverse direction coincides with the Y direction, as shown, for example, in Fig. 2. The word "transverse" also refers to a direction perpendicular to the parallel planes of the face plates 18 and 18'. The terms "structural channel," "structural cap," and "structural beam" are used interchangeably. The term "superbeam assembly" refers to an integrated support structure that includes a pair of face plates and a pair of attached cover plates that define a pair of corresponding coolant channels that cool each face plate. The term "structural channels" includes "structural beams"; they can have complex cross-sectional shapes, including, but not limited to: I-shaped beams, L-shaped beams, T-shaped beams, M-shaped beams, and zigzag-shaped beams.

[0022] Fig. Figure 1 shows a schematic perspective view of an example of a battery pack frame housing 8 for an electric vehicle with five large structural cross members 12, 12', etc., extending across the entire width of the battery pack frame housing 8 in the X direction. Also shown are two structural side members 20 and 20' of the frame housing, which extend in the Y direction across the entire length of the frame housing 8 and protect the batteries subjected to a lateral force F.

[0023] Fig. 2 shows a schematic perspective view of an example of a battery pack frame housing 8 supporting a battery pack 10 for an electric vehicle, including a plurality of superbeam assemblies 16, 16', etc., disposed between pairs of adjacent battery cells 26, 26' and oriented perpendicular to the frame housing supports 20 and 20', which protect against lateral forces F according to the present disclosure. The frame housing 8 further includes a pair of structural supports 6 and 6' aligned in the X direction.

[0024] Fig. 3A shows a schematic perspective view of an example of one half 14 of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. One half 14 of the superbeam assembly 16 includes a left front plate 18 extending longitudinally in the X-direction with a C-shaped left coolant channel cover plate 28 attached thereto having a perimeter 130 defining an internal coolant channel (see Fig. 4). The coolant inlet 22 and the coolant outlet 24 are not visible in this view. In this example, no peripheral flange(s) are attached to the front panel 18.

[0025] Fig. 3B shows a schematic cross-sectional view (end view) (section AA) of an example half section 14 of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, according to the present disclosure. Half section 14 of the superbeam assembly 16 includes a vertical faceplate 18 with a battery cell disposed adjacent the faceplate 18. A C-shaped coolant channel cover plate 28 is attached to the faceplate 18 around a perimeter 130 of the cover plate 28. The coolant channel 30 is defined on one side of the coolant channel 30 by the faceplate 18 and on the other side of the coolant channel 30 by the C-shaped coolant channel cover plate 28. The coolant channel 30 is hermetically sealed by a circumferential joint 130. The circumferential joint 130 may be a welded, brazed, or bonded joint.

[0026] Fig. Figure 4 shows a schematic cross-sectional view (end view) (section AA) of an example of a complete superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, with upper and lower structural channels 32 and 38, respectively, according to the present disclosure. The superbeam assembly 16 consists of two halves, a first half section 14 and a second half section 14' (which is a mirror image of the first half section 14). The superbeam assembly 16 includes a pair of vertically spaced, parallel left and right faceplates 18 and 18', respectively, extending longitudinally in the X direction. A pair of left and right battery cells 26 and 26' are located adjacent to the left and right faceplates 18 and 18', respectively. Left and right C-shaped coolant channel cover plates 28 and 28' are attached to the left and right front panels 18 and 18', respectively.The left and right coolant channel cover plates 28 and 28', respectively, form a pair of left and right C-shaped internal coolant channels 30 and 30', respectively. A pair of upper and lower air gaps 29 and 29', respectively, are located between the left and right front plates 18 and 18', respectively, and lie outside the left and right internal coolant channels 30 and 30', respectively. The presence of air gaps 29 and 29' between the adjacent left and right front plates 18 and 18' increases the elastic transverse compliance of the superbeam assembly 16 in the transverse direction (i.e., in the Y direction).

[0027] With further reference to Fig. 4, the upper structural channel 32 may include a T-shaped upper structural channel 34 having a hollow portion 44 of the web 47 and a pair of left and right integral upper flanges 36 and 36'. The left and right upper flanges 36 and 36' are integrally connected to the left and right front panels 18 and 18', respectively. The T-shaped upper structural channel 34 may be attached to the left and right upper flanges 36 and 36', for example, by a weld or braze joint. Alternatively, left and right adhesive strips 76 and 76' may be used to bond the T-shaped upper structural channel 34 to the left and right upper flanges 36 and 36', respectively. The T-shaped upper structural channel 34 may be made, for example, of extruded steel or an extruded aluminum alloy.In one example, the hollow portion 44 of the web 47 may be filled with a solid material that may be the same or different than the material used for the upper structural channel 32.

[0028] With further reference to Fig. 4, the lower structural channel 38 consists of a T-shaped lower structural channel 40 with a hollow portion 39 of the web 49 and a pair of left and right integral lower flanges 42 and 42', respectively. The left and right lower flanges 42 and 42' are integrally attached to the underside of the left and right front panels 18 and 18', respectively. The T-shaped lower structural channel 40 can be attached to the lower flanges 42 and 42', for example, by a weld or solder joint. Alternatively, left and right adhesive strips 76 and 76' can be used to bond the T-shaped lower structural channel 40 to the left and right lower integral flanges 42 and 42', respectively. The T-shaped lower structural channel 40 can be made, for example, of extruded steel or an extruded aluminum alloy.

[0029] In one example, the hollow portion 39 of the web 49 may be filled with a solid material, which may be the same or different than the material used to form the lower structural channel 38.

[0030] Fig. Figure 5 shows a schematic cross-sectional view (end view) (section DD) of an example of a complete superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, as well as upper and lower structural channels 32 and 38, respectively, according to the present disclosure. The superbeam assembly 16 consists of a pair of left and right, spaced-apart, parallel face plates 18 and 18' extending longitudinally in the X direction. The left and right battery cells 26 and 26' are not shown in this view. C-shaped, left and right coolant channel cover plates 28 and 28' are attached to the left and right face plates 18 and 18', respectively. The left and right coolant channel cover plates 28 and 28' define a pair of left and right C-shaped, internal coolant channels 30 and 30', respectively.This cross-sectional view shows the left and right coolant inlets 22 and 22' through which the coolant 70 and 70' is directed into the left and right coolant channels 30 and 30', respectively.

[0031] Fig. 6 shows a schematic cross-sectional view (section AA) of an example of an upper structural channel 32 according to the present disclosure. The upper channel 32 has a monolithic, T-shaped cross-section including a pair of left and right horizontal flanges 46 and 46' with an integral pair of vertical web portions 41 and 41', respectively. A cavity 44 is disposed between the pair of web portions 41 and 41'. The T-shaped upper structural channel 32 may be made of, for example, extruded steel or an extruded aluminum alloy. In one example, the cavity 44 may be filled with a solid material, which may be the same as or different from the material used to fabricate the upper structural channel 32.

[0032] Fig. Figure 7 shows a schematic perspective view of an example of one half 14 of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, as well as four examples of integral flange sections 90, 48, 92, and 54 according to the present disclosure. One half 14 of the superbeam assembly 16 includes a long face plate 18 extending longitudinally in the X direction. An attached, molded coolant channel cover plate 28 having a perimeter 130 defines an internal coolant channel (not visible in this view). See Fig. 4. Proximal and distal coolant inlets 22 and outlets 24, respectively, are located at opposite ends of the front plate 18, but are not visible in this view. The four integral flange sections 90, 48, 92, and 54 are integrally mounted to the front plate 18.

[0033] Fig. Figure 8 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions and two pairs of left and right integral longitudinal flange segments (48, 54) and (48', 54'), respectively, attached to left and right front panels 18 and 18', respectively, in accordance with the present disclosure. The left and right integral flange segments (48, 54) and (48', 54') are configured to receive battery cells 26 and 26', respectively. The remaining features of Fig. 8 are identical to Fig. 4, and these remaining features are not repeated here.

[0034] Fig. 9 shows a schematic exploded perspective view of an example of two half-beam sections 14 and 14' of a single superbeam assembly 16 with integrated structural, cooling and transverse elastic compliance functions, integral circumferential flanges (48, 54) and (48', 54'), and an upper structural channel 32 according to the present disclosure. The integral circumferential flanges include four integral circumferential flange segments 90, 48, 92, and 54 for the left half section 14 of the superbeam assembly 16 and flange sections 90', 48', 92', and 54' for the right half section 14' of the superbeam assembly 16. The left half section 14 of the superbeam assembly 16 includes a front plate 18 extending longitudinally along the X-direction with a C-shaped coolant channel cover plate 28 attached thereto having a circumference 130, 130' defining a C-shaped internal coolant channel (see Fig. 4). Proximal and distal coolant inlets 22, 22' and outlets 24, 24' and their corresponding proximal and distal openings 50, 52 and 50', 52', respectively, in the front plates 18 and 18' are located at opposite ends (i.e., distal and proximal ends) of the front plates 18, 18', which direct the flowing coolant 70 to the internal coolant channels 30, 30' (see Fig. 4) which are defined by the coolant channel cover plates 28 and 28'.

[0035] The next Fig. 10, Fig. 11, Fig. 12 and Fig. 13 show different coolant channel designs using the same pair of left and right front plates 18 and 18'.

[0036] Fig. 10 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Fig. 10 is identical to Fig. 4, except that the pair of left and right battery cells 26 and 26' have been removed for clarity, and transverse force arrows 108 and 108' have been added. The superbeam assembly 16 consists of a pair of parallel faceplates 18 and 18' separated by a gap 200. The width of the gap 200 can change (e.g., decrease) as the battery cells expand during charging and recharging cycles. C-shaped coolant channel cover plates 28 and 28' are attached to the left and right faceplates 18 and 18', respectively. The left and right coolant channel cover plates 28 and 28' define a pair of large-format, C-shaped, opposing left and right internal coolant channels 30 and 30', respectively. A pair of upper and lower air gaps 29 and 29' are located between the left and right front panels 18 and 18', respectively, and are outside the left and right inner coolant channels 30 and 30', respectively.The optional upper and lower structural channels 32 and 38 have been removed for clarity.

[0037] With further reference to Fig. 10, a series of inwardly directed transverse force arrows 108 and 108' are shown extending in the Y direction. These transverse compression forces (i.e., transverse pressure) can be generated from two different sources: (1) pre-compression of a battery pack 10 by means of preloaded bolts (not shown) extending through the frame housing 8 in the Y direction, and (2) progressive transverse expansion of the battery cells in the Y direction caused by repeated charge / discharge cycles while constrained by rigid constraints. The relatively thin, left and right C-shaped cover plates 28 and 28' are inherently elastically compliant in the transverse direction (i.e., because the thin cover plates 28 and 28' flex elastically like a spring when loaded by the inwardly directed transverse forces 108 and 108', respectively).

[0038] Fig. Figure 11 shows a schematic cross-sectional (end view) view (section AA) of an example superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, according to the present disclosure. Ten medium-sized, opposing left and right coolant channels 30, 30', etc. are shown. The relatively thin left and right cover plates 28 and 28' are inherently elastically compliant in the transverse direction (i.e., the Y direction) because they flex elastically like a spring when loaded by the transverse compressive forces 108 and 108', respectively. The optional upper and lower structural channels 32 and 38 have been removed for clarity.

[0039] Fig. Figure 12 shows a schematic cross-sectional (end view) view (section AA) of an example superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Nine medium-sized, alternating left and right coolant channels 30, 30', etc. are shown. The relatively thin left and right cover plates 28 and 28' are inherently elastically compliant in the transverse (i.e., Y-direction) direction because they flex elastically like a spring when loaded by the transverse compressive forces 108 and 108', respectively. A pair of upper and lower air gaps 29 and 29', respectively, are located between the left and right front plates 18 and 18', respectively, and lie outside the left and right internal coolant channels 30 and 30', respectively. The optional upper and lower structural channels 32 and 38 have been removed for clarity.

[0040] Fig. Figure 13 shows a schematic cross-sectional (end view) view (section AA) of an example superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions according to the present disclosure. Twenty small, opposing left and right coolant channels 30, 30', etc., are shown. The relatively thin, small left and right C-shaped cover plates 28 and 28' are inherently elastically compliant in the transverse (i.e., Y-direction) direction because they flex elastically like a spring when loaded by the transversely acting compressive forces 108 and 108', respectively. A pair of upper and lower air gaps 29 and 29', respectively, are located between the face plates 18 and 18', respectively, and lie outside the left and right internal coolant channels 30 and 30', respectively. The optional upper and lower structural channels 32 and 38 have been removed for clarity.

[0041] The examples discussed above in the Fig. 10, Fig. 11, Fig. 12 and Fig. 13 show four different configurations of coolant channels that allow the elastic compliance in the transverse direction to be tuned or adjusted to a specific desired level of elastic compliance, depending on the requirements of the battery pack design.

[0042] Fig. 14 shows a schematic perspective cross-sectional side view (section CC) of a single example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, upper and lower structural channels 32 and 38, respectively, and a pair of left and right horizontal frame housing structural supports 20 and 20' aligned along the X-direction, according to the present disclosure. The upper and lower structural channels 32 and 38, together with the front plate 18 and the coolant channel cover plate 28, extend the entire distance between one frame housing support 20 and the opposite frame housing support 20'. The coolant 70 flows horizontally in the Y-direction. The left and right frame housing side supports 20 and 20' are aligned perpendicular to the upper and lower structural channels 32 and 38, respectively, which support the battery cells (see Fig. 4) and the coolant channels (see Fig. 4) when subjected to a lateral force F in the Y direction.

[0043] Fig. Figure 15 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions and upper and lower structural channels 72 and 74, respectively, according to the present disclosure. The left and right battery cells 26 and 26' are not shown for clarity. The lower structural channel 74 consists of a pair of L-shaped channels 42 and 42'. Details of the upper structural channel 72 are discussed in the discussion of Fig. 16 shown.

[0044] Fig. 16 shows a schematic orthotropic cross-sectional view (end view) (section AA) of an example of an upper structural channel 72 according to the present disclosure. The upper structural channel 72 has an M-shaped cross-section and includes a horizontal cover plate 80 with an integral pair of left and right vertical sidewalls 86 and 86' spanning the left and right vertical extensions 97 and 97' of the left and right front panels 18 and 18', respectively. The upper structural channel also includes an integral, V-shaped central web portion 88. The central portion 44 of the V-shaped central web portion 88 may be hollow. In some examples, the left and right integral sidewalls 86 and 86' may be attached to the left and right upper vertical extensions 97 and 97' of the left and right front panels 18 and 18' with left and right vertical adhesive strips 152 and 152', respectively.In one example, the cavity 72 may be filled with a solid material, which may be the same or different than the material used to form the upper structural channel 72.

[0045] Fig. Figure 17 shows a schematic cross-sectional view (end view) (section AA) of an example of a supercarrier assembly faceplate 18 with a pair of integral vertical extensions 97 and 97' according to the present disclosure. The faceplate 18 extends vertically across the top and bottom ends of the battery cell 26 with integral, straight, vertical top and bottom extensions 97 and 98, respectively. The coolant channels are not shown for clarity.

[0046] Fig. 18 shows a schematic cross-sectional view (section AA) of an example of a superbeam assembly having integral L-shaped upper and lower peripheral flanges 48 and 54, respectively, and a battery cell 26 adjacent to the faceplate 18, according to the present disclosure. The addition of the integral upper and lower peripheral flanges 48 and 54 increases the bending rigidity (and load-bearing capacity) of the superbeam assembly 16. The flange portions 48 and 54 of the faceplate 18 both face inward, toward the battery cell 26 (i.e., in the negative Y direction). The coolant channels are not shown for clarity. The width of the flanges 48 and 54 may be less than or equal to half the width of the battery cell 26 (to enable compact mounting of multiple side-by-side superbeam assemblies).

[0047] Fig. Figure 19 shows a schematic cross-sectional view (end view) (section AA) of an example superbeam assembly faceplate 18 with integral, L-shaped upper and lower peripheral flanges 48 and 110 according to the present disclosure. The upper flange 48 faces inward (i.e., to the left) and the lower flange 110 faces outward (i.e., to the right). The coolant channels are not shown for clarity. The width of the flanges 48 and 110 may be less than or equal to half the width of the battery cell 26 (to enable compact mounting of multiple side-by-side superbeam assemblies).

[0048] Fig. Figure 20 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions and upper and lower structural channels 72 and 118, respectively, according to the present disclosure. The upper structural channel 72 is in Fig. 16 in more detail. The left and right upper extensions 97 and 97' of the left and right front panels 18 and 18' respectively are inserted into the upper structural channel 72 as shown in Fig. 16. The lower ends of the left and right front panels 18 and 18' include outwardly directed left and right flange portions 116 and 116', respectively. The pair of adjacent battery cells is not shown for clarity. The lower structural channel 118 may have an I-shaped cross-section.

[0049] Fig. Figure 21 shows a schematic cross-sectional view (end view) (section AA) of an example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions, as well as an upper structural channel 122 and a lower structural channel 78 and 78', according to the present disclosure. The upper structural channel 122 may have an inverted U-shaped cross-sectional shape 120 spanning the left and right upper extensions 97 and 97' of the left and right front panels 18 and 18', respectively. The U-shaped channel 120 may be bonded to the left and right upper extensions 97 and 97' of the left and right front panels 18 and 18', respectively. The lower left and right ends 78 and 78' of the left and right front panels 18 and 18', respectively, include left and right integral flanges 78 and 78' having a dogleg or zigzag cross-sectional shape.

[0050] Fig. 22 shows a schematic cross-sectional top view (section BB) of an example of a superbeam assembly 16 with integrated structural, cooling, and transverse elastic compliance functions and integral peripheral flanges 90 and 92, according to the present disclosure. The battery cells 26, 26', 26'', and 26''' are located between the integral peripheral flanges 90 and 92 and are adjacent to the faceplate 18. An optional compliant layer 106 of thermal interface material (TIM) may be disposed between the battery cell 26 and the faceplate 18. The TIM layer 106 may be adhesive and used to bond the battery cell 26 to the faceplate 18. The coolant channel 30 is defined on one side by the faceplate 18 and on the other side by the cover plate 28.The coolant 70 flows into the inlet opening 22, then flows horizontally in the X direction through the coolant channel 30 and finally exits again through the outlet opening 24.

[0051] Fig. 23 shows a schematic perspective view of an example of an electric motor vehicle 94 with a rechargeable battery pack 10, according to the present disclosure. The electric motor vehicle 94 includes a vehicle body 96, a passenger compartment 98, a plurality of road wheels 100, 100', etc., attached to the vehicle body 96, and a rechargeable battery pack 10 located inside the electric motor vehicle 94. The electric motor vehicle 94 further includes an electric traction motor 104 attached to the vehicle body 96, which drives one or more of the road wheels 100, 100', etc., that propel the electric motor vehicle 94. The rechargeable battery pack 10 is attached to the vehicle body 96 and electrically connected to the traction motor 104 via the power cable 102.

[0052] Fig. Figure 24 shows a schematic perspective view of an example of a supercarrier assembly 132 with a complete set of left and right battery cells 26, 26', etc., according to the present disclosure. The assembly 132 consists of a pair of left and right front plates 18 and 18' with left and right coolant inlets 22 and 22', and four pairs of left and right battery cells (26, 26'), etc., located on either side of the left and right front plates 18 and 18', respectively, and arranged along the length of the assembly 132 in the X direction. The internal coolant channels are not visible in this figure. The structural channels 78 and 78' are shown at the bottom left and right.

[0053] Fig. Figure 25A shows a schematic side view of an example of a pair of vertical end structure channels 190 and 192 attached to the proximal and distal ends 194 and 196, respectively, of a supercarrier assembly 16 according to the present disclosure. The supercarrier assembly 16, in this example, includes a right front panel 18.

[0054] Fig. Figure 25B shows a schematic top view (section BB) of an example of a pair of vertical end structural channels 190 and 192 attached to the proximal and distal ends 194 and 196, respectively, of a superbeam assembly 16 according to the present disclosure. The superbeam assembly 16 includes a right front plate 18 and a left front plate 18', as well as a left coolant channel cover plate 28' and a right coolant channel cover plate 28. The superbeam assembly 16 further includes a left coolant channel 30' and a right coolant channel 30. The end structural channels 190 and 192 can hermetically seal the proximal and distal ends 194 and 196, respectively, of the left and right coolant channels 30 and 30'.

[0055] Fig. Figure 26 shows a schematic cross-sectional view (section AA) of an example of four adjacent supercarrier assemblies supporting five battery cells 26A, 26B, 26C, 26D, and 26E, according to the present disclosure. The supercarrier assemblies 16A, 16B, 16C, and 16D are aligned parallel to each other, with the battery cells 26A, 26B, 26C, 26D, and 26E being disposed adjacent to and between adjacent pairs of supercarrier assemblies (16A, 16B), (16B, 16C), and (16C, 16D), respectively. The total width of each supercarrier assembly 16A, 16B, 16C or 16D may be less than or equal to the width of a battery cell 26A, 26B, 26C, 26D or 26E to enable a compact assembly of multiple supercarrier assemblies and battery cells side by side in the transverse direction (Y-axis).

[0056] Fig. Figure 27 shows a schematic perspective of an example of seven assembled supercarrier assemblies 16 containing eight rows of left and right battery cells 26, 26', etc., arranged in parallel rows in a battery pack assembly 10 according to the present disclosure. The supercarrier assembly 16 is an example of the seven parallel supercarrier assemblies 16, 16', etc., accommodating a total of thirty-two battery cells 26, 26', etc. A pair of left and right frame housing supports 20 and 20' are longitudinally aligned along the Y direction and attached to the proximal and distal ends of the upright faceplates 18, 18', etc. The left and right coolant channels 30 and 30' located between the adjacent faceplates 18 and 18' are not shown in this figure. The left and right coolant inlet and outlet pipes 160, 162 and 160', 162' are located inside the frame housing supports 20 and 22, respectively.20' and run parallel to the Y-direction. The left and right inlet / outlet supply pipes 160, 162 and 160', 162' supply coolant 70 to the left and right coolant channels 30 and 30' located between adjacent front plates 18 and 18' (see, for example, . Fig. 4).

[0057] Fig. 28 shows a schematic cross-sectional view (section AA) of an example of a supercarrier assembly 16 including left and right battery cells 26 and 26' with upper and lower TMP suppression channels 138 and 139, respectively, according to the present disclosure. The upper TMP suppression channel 138 may have a rectangular (or circular) cross-section, with a lower opening 144 located at the bottom of the upper channel 138 and fluidly communicating with the air gap 29 located between the left and right front panels 18 and 18'. In some examples, the upper interior volume 140 (located within the TMP suppression channel 138) may be filled with air.Thermal modeling of the transient temperature rise in a battery cell adjacent to a battery cell undergoing a TMP event predicts that the peak temperature of the battery cell after 100 seconds can be reduced by approximately 32°C by using the upper TMP suppression channel 138. In another example, the upper interior volume 140 can be filled with a thermal phase change material (not shown) that absorbs heat and reduces the temperature rise in adjacent battery cells during a TMP event.

[0058] With further reference to Fig. 28, the figure also shows an example of a lower TMP suppression channel 139 having a lower internal volume 141 and an upper opening 145 disposed at the top of the lower channel 139. Both the upper and lower TMP suppression channels 138 and 139, respectively, can be attached to the front panel flanges 48, 48' and 54, 54', respectively, using the left and right upper adhesive strips 142 and 142', respectively, and the left and right lower adhesive strips 143 and 143', respectively. The left and right adhesive strips 142, 142', 143, and 143' may be comprised of an adhesive material that melts at a relatively low temperature (e.g., 100°C), which may serve as a "thermal fuse" that melts, detaches, and thermally isolates a hot battery cell (e.g., cell 26) experiencing a thermal management event from an adjacent, cold battery cell (e.g., cell 26') to prevent thermal management propagation.In addition, the vertical height and horizontal width of the upper and lower TMP suppression channels 138 and 139, respectively, may be increased (independently or in combination) to increase the thermal resistance path between adjacent left and right battery cells 26 and 26' by providing a longer conduction path between adjacent left and right battery cells 26 and 26'.

[0059] Fig. Figure 29A shows a schematic cross-sectional view (section AA) of an example of an upper TMP suppression channel 138 according to the present disclosure. The suppression channel 138 has a rectangular cross-section; an interior volume 140 (which in some examples may be filled with air or a phase-change material); and a lower opening 144.

[0060] Fig. Figure 29B shows a schematic cross-sectional view (section AA) of an example of an alternative design of a TMP suppression channel 146 (upper or lower channel) with four "Z-shaped" left and right bellows segments 150 and 150', according to the present disclosure. The four Z-shaped, left and right bellows segments 150 and 150' are used to increase the total thermal path length between adjacent battery cells, which increases the thermal resistance from one side of the TMP suppression channel 146 to the opposite side of the channel 146. The suppression channel 146 has a bellows-shaped cross-section, an interior volume 148 (which, in some examples, may be filled with air or a phase-change material), and a bottom opening 144.

[0061] Fig. Figure 30 shows a schematic perspective cross-sectional view (section A-A) of an example of an upper TMP suppression channel 138 having a series of longitudinal slots 170, 170', etc., according to the present disclosure. The TMP suppression channel 138 has a horizontal, longitudinally extending upper plate 176, a lower opening 144 located at the bottom of the upper channel 138, and a central volume 140 that may be hollow or filled with a phase-change substance (wax, solder, etc.) that has a high heat absorption capacity. A series of longitudinal slots 170, 170', etc. are arranged longitudinally along the X direction, which may be centered in the Y direction. The purpose of the series of longitudinal slots 170, 170' is to reduce the effective thermal conductivity in the transverse direction (i.e., in the Y direction) by inserting a series of openings that reduce or block heat conduction in the transverse direction.This serves to compensate for the temporary temperature rise in a battery cell 26 (see . Fig. 4) adjacent to a battery cell 26' undergoing a TMP event. In one example, multiple rows of longitudinal slots 170, 170', etc., may be arranged in the upper longitudinal plate 176 of the TMP suppression channel 138. In another example, the longitudinal slots 172, 172', etc., may only partially penetrate the wall thickness of the upper longitudinal plate 176 to ensure a hermetic seal of the TMP suppression channel 138.

[0062] Fig. 31 shows a schematic perspective cross-sectional view (section AA) of an example of an upper TMP suppression channel 138 having a series of multiple perforations 172, 172' according to the present disclosure. The TMP suppression channel 138 has a horizontal, longitudinally extending upper plate 176, a lower opening 144 located at the bottom of the upper channel 138, and a central volume 140 that may be hollow or filled with a phase change substance (wax, solder, etc.) that has a high heat absorption capacity. A series of multiple perforations 172, 172', etc., are arranged along the X-direction. The purpose of this series of multiple perforations 172, 172' is to increase the effective thermal conductivity in the transverse direction (i.e.,in the Y direction) by inserting a series of openings that reduce or block heat conduction in the transverse direction, which serves to reduce the temporary temperature rise in a battery cell 26 (see . Fig. 4) disposed adjacent to a battery cell 26' subject to a TMP event. In one example, the perforations may only partially penetrate the wall thickness of the upper longitudinal plate 176, thereby maintaining a hermetic seal of the TMP suppression channel 138.

[0063] Fig. 32 shows a schematic perspective cross-sectional view (section A-A) of an example of an upper TMP suppression channel 138 with a central, longitudinal, recessed groove (or partial slot) 174 according to the present disclosure. The TMP suppression channel 138 has a horizontal, longitudinal upper plate 176, a lower opening 144 disposed at the bottom of the upper channel 138, and a central volume 140 that may be hollow or filled with a phase change substance (wax, solder, etc.) that has a high heat absorption capacity. One or more recessed longitudinal grooves 174 (only one groove 174 is shown) may be disposed along the X-longitudinal direction at a mid-Y-direction position. The purpose of the one or more recessed grooves 174 is to increase the effective thermal conductivity in the transverse direction (i.e.,in the Y direction) by locally reducing the wall thickness of the upper longitudinal plate 176 to reduce transverse heat conduction in the Y direction. This configuration serves to mitigate the temporary temperature rise in a regular battery cell 26 (see . Fig. 4) located adjacent to a battery cell 26' in which a TMP event is taking place.

[0064] Fig. 33 shows a schematic perspective view of a battery pack frame enclosure 8 having a single superbeam assembly 16 aligned longitudinally (side to side) in the X direction, according to the present disclosure. The frame enclosure 8 consists of parallel side beams 20 and 20' and parallel front and rear beams 6 and 6', respectively. The parallel front panels 18 and 18' are aligned longitudinally (side to side) in the X direction. With a superbeam assembly 16 aligned longitudinally (side to side) in the X direction, the front panels 18 and 18' (and any upper and / or lower structural channels (not shown)) provide structural support to the internal coolant channels (not shown) and the battery cells (not shown) when a side beam 20 or 20' is subjected to a lateral force (see Fig. 1 and Fig. 2).

[0065] Fig. Figure 34 shows a schematic perspective view of a battery pack frame housing 8 with a single superbeam assembly 16 aligned longitudinally (front to back) in the Y direction, according to the present disclosure. The parallel front panels 18 and 18' are also aligned longitudinally (front to back) in the Y direction.

[0066] In some examples, the coolant flow 70 in the left and right coolant channels 30 and 30' (see e.g. Fig.4) flow in the same direction (e.g., parallel to the X-axis). In other examples, the coolant 70 may flow in opposite (i.e., countercurrent) directions (e.g., parallel to the X-axis). For example, the coolant in the left channel 30 may flow in the positive X-direction, while the coolant in the right channel 30' counterflows in the negative X-direction. Alternatively, the coolant flowing in the left channel 30 may flow in the negative X-direction, while the coolant flowing in the right channel 30' may counterflow in the positive X-direction. The use of a counterflow coolant loop may result in more uniform battery temperatures across a bank of battery cells 26, 26', etc.

[0067] In some examples, the width of a supercarrier assembly 16 may be less than or equal to the width of a battery cell 26, allowing for a compact arrangement of adjacent battery cells 26, 26', etc.

[0068] In some examples, the upper and / or lower TMP suppression channels 138 and 139 may be made of a ceramic material with low thermal conductivity (e.g., alumina, silicon carbide, or silicon nitride). Alternatively, the TMP suppression channels 138 and / or 139 may be made of a fiber-reinforced plastic composite (FRP) material that has low thermal conductivity and a high strength-to-weight ratio. The FRP composite material may have fibers oriented primarily in the longitudinal direction (X-direction), e.g., a 1-D FRP.

Claims

[1] Multifunctional superbeams with integrated structural, cooling and transverse elastic compliance functions, comprising: (a) a left front panel; (b) a right front panel; (c) one or more left coolant channel cover plates; (d) one or more right coolant channel cover plates; (e) one or more left coolant channels defined by the left front panel and one or more left coolant channel cover plates; and (f) one or more right coolant channels defined by the right front panel and the one or more right coolant channel cover plates; wherein the one or more left coolant channel cover plates are attached to the left front panel; wherein the one or more right coolant channel cover plates are attached to the right front panel; and with the left front panel aligned parallel to the right front panel. [2] Multifunctional supercarrier according to claim 1, further comprising: a left coolant inlet located at a proximal end of the left front panel; a left coolant outlet located at a distal end of the left front panel; a right coolant inlet located at a proximal end of the right front panel; and a right coolant outlet located at a distal end of the right front panel. [3] Multifunctional supercarrier according to claim 1, wherein the one or more left coolant channels have a C-shaped cross-section; and wherein the one or more right coolant channels have a C-shaped cross-section. [4] Multifunctional supercarrier according to claim 1, further comprising a left battery cell disposed adjacent to the left front panel; and further comprising a right battery cell disposed adjacent to the right front panel. [5] Multifunctional supercarrier according to claim 4, further comprising a left thermal interface material (TIM) disposed between the left battery cell and the left front panel; and further comprising a right thermal interface material (TIM) disposed between the right battery cell and the right front panel. [6] The multifunctional supercarrier according to claim 1 further comprises an upper structural channel attached to the left front panel and the right front panel. [7] Multifunctional supercarrier according to claim 6, wherein the upper structural channel has a T-shaped or M-shaped cross-section. [8] Multifunctional superbeams with integrated structural, cooling and transverse elastic compliance functions, comprising: (a) a left front panel; (b) a right front panel; (c) one or more left coolant channel cover plates; (d) one or more right coolant channel cover plates; (e) one or more left coolant channels defined by the left front plate and the one or more left coolant channel cover plates; (f) one or more right coolant channels defined by the right front panel and the one or more right coolant channel cover plates; (g) an upper thermal runaway propagation suppression (TRP) duct attached to an upper portion of the supercarrier; and (h) a lower thermal runaway propagation (TRP) suppression duct mounted on a lower portion of the supercarrier; and wherein the left faceplate is aligned parallel to the right faceplate. [9] Multifunctional supercarrier according to claim 8, further comprising: a left upper flange integrally connected to the left front panel; a right upper flange integrally connected to the right front panel; a left lower flange integrally connected to the left front panel; a right lower flange integrally connected to the right front panel; a left upper thermal fuse located between the upper TRP suppression channel and the left upper flange; a right upper thermal fuse located between the upper TRP suppression channel and the right upper flange; a left lower thermal fuse located between the lower TRP suppression channel and the left lower flange; and a right lower thermal fuse located between the lower TRP suppression channel and the right lower flange. [10] Electric vehicle comprising: an electric vehicle body; a battery pack arranged in the electric vehicle body; and one or more integrated multi-function super-beam structures arranged within the battery pack, each integrated multi-function super-beam structure comprising: (a) a left front panel; (b) a right front panel; (c) one or more left coolant channel cover plates; (d) one or more right coolant channel cover plates; (e) one or more left coolant channels defined by the left front plate and by the one or more left coolant channel cover plates; and (f) one or more right coolant channels defined by the right front panel and the one or more right coolant channel cover plates; and wherein the left front panel is aligned parallel to the left front panel.

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