COOLING SYSTEM DISTRIBUTOR FOR A BATTERY MODULE

Abstract

A cooling system manifold for an accumulator module (22), wherein the accumulator module (22) has at least one accumulator cell (32) and at least one temperature control component (50) having a flow path with a feed port (52) for receiving coolant (34) and a return port (54) for discharging coolant (34), the cooling system manifold comprising: a supply manifold (57) attachable to the accumulator module (22) for supplying coolant (34) to the at least one temperature control component (50) in the accumulator module (22), wherein the supply manifold (57) comprises a separately formed first part (98) of the supply manifold (57) connected to a second part (100) of the supply manifold (57) to form an internal supply channel, wherein the first part (98) of the supply manifold (57) comprises a supply nozzle (68) that directs the coolant (34) into the internal supply channel, wherein the second part (100) of the supply manifold (57) comprises an outlet that directs the coolant (34) from the internal supply channel to the feed nozzle (52), a first seal (120) arranged in the outlet, the first seal (120) having a first portion (132) sealed against the outlet and a second portion (136) sealable against the feed nozzle (52), a withdrawal manifold (59) attachable to the accumulator module (22) for withdrawing coolant (34) from the at least one temperature control component (50) in the accumulator module (22), wherein the withdrawal manifold (59) comprises a separately formed first portion (98) of the withdrawal manifold (59) connected to a second portion (100) of the withdrawal manifold (59) to form an internal withdrawal channel, wherein the first portion (98) of the withdrawal manifold (59) comprises a withdrawal port that directs coolant (34) from the internal withdrawal channel, and the second portion (100) of the withdrawal manifold (59) comprises an inlet that directs coolant (34) from the return port (54) to the internal withdrawal channel, and a second seal (120) disposed within the inlet, the second seal (120) having a first portion (132) sealed against the inlet and a second portion (136) sealable against the return port (54), wherein the first part (98) of the supply manifold (57) and the second part (100) of the supply manifold (57) are separately injection-molded and comprise connecting elements which connect the first part (98) of the supply manifold (57) to the second part (100) of the supply manifold (57) and form a seal which holds the coolant (34) in the inner supply channel, wherein the first seal (120) is arranged within the outlet either before or after the joining of the first part (98) of the supply manifold (57) and the second part (100) of the supply manifold (57), wherein the first part (98) of the extraction manifold (59) and the second part (100) of the extraction manifold (59) are separately injection-molded and comprise connecting elements which connect the first part (98) of the extraction manifold (59) to the second part (100) of the extraction distributor (59) and form a seal that holds the coolant (34) in the inner extraction channel,and wherein the second seal (120) is arranged within the inlet either before or after the first part (98) of the extraction manifold (59) and the second part (100) of the extraction manifold (59) are joined together, , wherein the outlet comprises an inner surface, the outlet inner surface having a step feature (130) formed in the injection-molded part, the first portion (132) of the first seal (120) having an outer diameter that contacts the step feature (130) of the outlet and prevents removal of the first seal (120) from the outlet away from the first part (98) of the supply manifold (57) and allows the supply manifold (57) to be removed from the accumulator module (22), the first seal (120) remaining in the supply manifold (57), and the inlet has an inner surface, the inlet inner surface having a step feature (130) formed in the injection-molded part, the first portion (132) of the second seal (120) having an outer diameter,which contacts the step feature (130) of the inlet and prevents the removal of the second seal (120) from the inlet away from the first portion of the extraction manifold (59) and allows the extraction manifold (59) to be removed from the accumulator module (22) with the second seal (120) remaining in the extraction manifold (59).

Description

[0001] The present disclosure relates to a cooling system manifold for a battery module that is part of a rechargeable energy storage system. More specifically, the present disclosure relates to a detachable manifold with an integrated seal for providing a heat transfer fluid flow for a cooled battery module.

[0002] Electric vehicles and hybrid vehicles use a rechargeable, high-voltage energy storage system consisting of a series of battery modules, each containing a number of battery cells. These electric and hybrid vehicles typically require multiple battery cells to meet the vehicle's power and energy needs. The battery modules are often located under the body, centered between the front and rear wheels.

[0003] Battery cells, particularly the high-voltage type described above, generate significant amounts of heat during continuous operation. Over time, the heat generated can degrade the efficiency and overall structural integrity of the battery module. Thermal management systems are therefore used to precisely control the temperature of the battery module. In one type of thermal management system, heat transfer fluid circulates to and from temperature control components, such as belts or cold plates located between the battery cells. These cooling systems incorporate sealing elements integrated into the belts or cold plates and are not serviceable. Although effective, there is a need in the art for improved coolant system designs that allow for inline rework or maintenance of the cooling system.

[0004] WO 2018 / 206895 A1 discloses a heat exchanger for a vehicle, comprising a pipe for circulating a heat transfer fluid, the ends of which penetrate into a collecting container. Each collecting container has a collector with a first through-hole for the pipe and a cover with a second through-hole for the pipe, which delimits at least one chamber for circulating the heat transfer fluid. The pipe and the cover are mechanically connected to the collector, and the collecting container contains at least one seal, which is arranged, on the one hand, between the cover and the pipe and, on the other hand, between the collector and the cover. WO 2022 / 022759 A1 teaches a heat exchanger arrangement comprising an internal heat exchanger circuit with an inlet for supplying and an outlet for discharging a heat transfer medium, and at least one battery cell or battery module, wherein a molded seal made of elastomeric material is used.A portion of the internal heat exchanger circuit is defined by two parallel surfaces and the molded gasket, wherein at least one of the parallel surfaces is a battery cell or battery module surface, and the circuit is connected to the inlet at its first end and to the outlet at its second end.

[0005] It is an object underlying the invention to provide an improved cooling system manifold for a battery module.

[0006] This object is achieved by a cooling system distributor according to claim 1.

[0007] The invention relates to a cooling system distributor for a battery module according to claim 1.

[0008] In one aspect, the second part of the supply manifold includes a plurality of attachment sections attached to the battery module with releasable fasteners, and the second part of the removal manifold includes a plurality of attachment sections attached to the battery module with releasable fasteners.

[0009] In another aspect, the cooling system manifold includes compression limiters disposed in the attachment portions of the second part of the supply manifold and in the attachment portions of the second part of the extraction manifold. The compression limiters limit the compression of the attachment portions of the supply manifold by the releasable fasteners that attach the supply manifold to the accumulator module and limit the compression of the attachment portions of the extraction manifold by the releasable fasteners that attach the extraction manifold to the accumulator module.

[0010] In another aspect, the attachment portions of the second part of the supply manifold have two alignment holes that receive the insertion of alignment pins on the battery module and align the supply manifold with the battery module, and the attachment portions of the second part of the removal manifold have two alignment holes that receive the insertion of alignment pins on the battery module and align the removal manifold with the battery module.

[0011] In another aspect, a coolant supply line includes a supply attachment bracket and supplies coolant to the supply manifold, and a coolant return line includes a return attachment bracket and withdraws coolant from the withdrawal manifold. The first portion of the supply manifold includes a releasable fastener engagement opening adjacent the supply port, and the first portion of the withdrawal manifold includes a releasable fastener engagement opening adjacent the withdrawal port.The coolant supply line is attached to the supply nozzle, the supply mounting bracket being attached to the supply manifold with a fastener in the fastener engaging opening of the supply manifold, and the coolant return line is attached to the extraction nozzle, the return mounting bracket being attached to the extraction manifold with a fastener in the fastener engaging opening of the extraction manifold.

[0012] According to the invention, the first part of the supply manifold and the second part of the supply manifold are separately injection-molded and comprise connecting elements that connect the first part of the supply manifold to the second part of the supply manifold and form a seal that holds the coolant in the inner supply channel, wherein the first seal is arranged within the outlet either before or after the first part of the supply manifold and the second part of the supply manifold are joined together, wherein the first part of the extraction manifold and the second part of the extraction manifold are separately injection-molded and comprise connecting elements that connect the first part of the extraction manifold to the second part of the extraction manifold and form a seal that holds the coolant in the inner extraction channel,and wherein the second seal is disposed within the inlet either before or after joining the first part of the extraction manifold and the second part of the extraction manifold.,

[0013] In another aspect, the first portion of the supply manifold includes a rear stop formed in the molded part that is aligned with the outlet, the rear stop of the supply manifold limiting movement of the first seal in the outlet toward the first portion of the supply manifold, the first portion of the extraction manifold includes a rear stop formed in the molded part that is aligned with the inlet, and the rear stop of the extraction manifold limiting movement of the second seal in the inlet toward the first portion of the extraction manifold.

[0014] According to the invention, the outlet comprises an inner surface, the outlet inner surface having a step feature formed in the injection molded part, the first portion of the first seal having an outer diameter contacting the step feature of the outlet and preventing removal of the first seal from the outlet away from the first portion of the supply manifold and allowing the supply manifold to be removed from the accumulator module, the first seal remaining in the supply manifold, and the inlet comprises an inner surface, the inlet inner surface having a step feature formed in the injection mold, the first portion of the second seal having an outer diameter contacting the step feature of the inlet and preventing removal of the second seal from the inlet away from the first portion of the extraction manifold and allowingthat the extraction manifold can be removed from the accumulator module, with the second seal remaining in the extraction manifold.

[0015] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0016] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. Fig. 1 shows a schematic view of an exemplary motor vehicle having a rechargeable energy storage system with a plurality of battery modules and a cooling arrangement according to the principles of the present disclosure. Fig. 2 shows battery modules with the cooling arrangement in an isometric perspective view. Fig. 3 shows temperature control components and accumulators of an accumulator module in an isometric perspective view. Fig. 4 shows a dual function distributor according to the principles of the present disclosure in an isometric perspective view. Fig. 5A shows a first portion of a dual function distributor according to the principles of the present disclosure in an isometric perspective view. Fig. 5B shows a second portion of a dual function manifold according to the principles of the present disclosure in an isometric perspective view. Fig. 5C shows the attachment of a first and a second part of a dual function manifold according to the principles of the present disclosure in an isometric perspective view. Fig. 6A shows a first portion of a single function distributor according to the principles of the present disclosure in an isometric perspective view. Fig. 6B shows a second portion of a single function manifold according to the principles of the present disclosure in an isometric perspective view. Fig. 6C shows the attachment of a first and a second part of a single function manifold according to the principles of the present disclosure in an isometric perspective view. Fig. 7 shows a seal in an isometric perspective view. Fig. Figure 8 shows the dual function distributor in a cross-sectional view, seen in the direction of arrows 8-8 in Fig. 4. Fig. Figure 9 shows a formed single function distributor in a cross-sectional view, seen in the direction of arrows 9-9 in Fig. 6C. Fig. Figure 10 shows the dual function distributor attached to a battery module in a cross-sectional view, seen in the direction of the arrows 10-10 in Fig. 2. Fig. Figure 11 shows a single function distributor attached to a battery module in a cross-sectional view, seen in the direction of arrows 11-11 in Fig. 2. Fig. 12 shows a compression limiter in an isometric perspective view. Fig. 13 a mounting section of a distributor in an isometric perspective view.

[0017] The following description is merely exemplary and is not intended to limit the present disclosure, application, or uses.

[0018] With reference to Fig. 1, a rechargeable energy storage system 18 is shown having a cooling assembly 20 and battery modules 22 in accordance with the principles of the present disclosure. The cooling assembly 20 is configured to provide cooling for the battery modules 22, as described in more detail below. The rechargeable energy storage system 18 is illustrated with a vehicle 24. The vehicle 24 shown is exemplary. The vehicle 24 is preferably an electric vehicle or hybrid vehicle having wheels 26 driven by electric motors / inverters 28. The electric motors / inverters 28 receive their motive power from the battery modules 22. Although the vehicle 24 is illustrated as a passenger vehicle, it should be understood that the cooling assembly 20 and the battery modules 22 may be used for other types of vehicles.The cooling assembly 20 and the battery modules 22 can be used, for example, in watercraft, such as boats, or in aircraft, such as drones or passenger aircraft. Furthermore, the cooling assembly 20 and the battery modules 22 can be used as a stationary power source, separate from and independent of the vehicle.

[0019] The rechargeable energy storage system 18 typically includes a battery carrier 30 connected to the vehicle 24. The battery carrier 30 provides structural support for one or more battery cells 32 (only one of which is shown) arranged within the battery modules 22. The battery cells 32 may be cylindrical lithium-ion battery cells, as shown. However, it should be understood that any type of battery cell 32 may be used as long as the battery cell 32 is compatible with the cooling assembly 20.

[0020] With reference now to Fig. 2 and Fig. 3, the cooling assembly 20 is illustrated relative to two exemplary versions of the battery modules 22. The cooling assembly 20 is configured to circulate a coolant 34 therein to cool the battery cells 32 in the battery modules 22 through heat transfer. The cooling assembly 20 forms part of a larger battery thermal management system 36, which generally includes a pump 38, a heat exchanger 40, and a recovery tank 42. The battery thermal management system 36 may include various other components, including temperature and humidity sensors, heating, ventilation, and air conditioning (HVAC) components, valves, and electronic controls, without departing from the scope of the present disclosure.Generally, the pump 38 is in fluid communication with the recovery tank 42 and pumps the coolant 34 from the recovery tank 42 into a coolant supply line 44 of the cooling assembly 20. The cooling assembly 20 directs the coolant 34 to the accumulator modules 22 to cool the accumulator cells 32. The coolant 34 is then returned from the cooling assembly 20 through a coolant return line 46 and supplied to the heat exchanger 40. The heat exchanger 40 removes heat from the coolant 34, e.g., using a liquid-to-air heat exchanger with a fan, although other types of heat exchangers may also be used. The coolant 34 is returned to the recovery tank 42.

[0021] The cooling assembly 20 includes one or more detachable manifolds 48 connected to temperature control components 50 in the battery module 22. The detachable manifolds 48 supply coolant 34 to or remove coolant 34 from a coolant flow path in the temperature control components 50 to regulate the temperature of the battery cells 32 in the battery module 22. The temperature control components 50 can take various forms depending on the shape or type of the battery cells 32 in the battery module 22. As shown in Fig. 3, the temperature control components 50 may, for example, be configured as bands to receive the cylindrical battery cells 32. Other shapes of the temperature control components 50 include a relatively flat surface for receiving flat-surface battery cells and may be referred to as a cold plate. The temperature control components 50 include a feed port 52 and a return port 54 for supplying and removing coolant 34 from the internal coolant flow path, respectively. The feed ports 52 are typically located below the return ports 54 such that the coolant 34 flowing through the internal coolant flow path enters at a low level and exits at a higher level. The manifolds 48 may take various functional forms to engage the temperature control components 50 within the battery module 22.The manifold 48 may, for example, be a dual-function manifold 56 that supplies coolant 34 to and removes coolant 34 from a temperature control component 50, or it may be a single-function manifold 58 that is either a supply manifold 57 that supplies coolant 34 to a temperature control component 50, or a removal manifold 59 that removes coolant 34 from a temperature control component 50. As described in more detail below, each of these manifolds 48 comprises separately formed parts that are connected to one another, and the single-function manifold 58 has a single internal flow channel to support a single coolant flow function, and the dual-function manifold 56 has two internal flow channels to support two coolant flow functions. The parts are separately injection-molded and may be made of different materials, e.g.Made of polyamide, polypropylene, and glass fiber reinforced PA66+GF30. Other materials can also be used, selected to provide the desired functions and capabilities.

[0022] With reference to Fig. 2, Fig. 4, Fig. 5A, Fig. 5B, Fig. 5C and Fig. 8, the dual-function manifold 56 includes a first portion 60 and a second portion 62. Each portion 60, 62 is separately injection-molded and, as described above, may be made of a variety of materials, with the portions being joined together to form the dual-function manifold 56. The first portion 60 includes a first cavity 61 and a second cavity 63, which, when joined to the second portion 62, respectively define an internal supply flow channel 64 and an internal bleed flow channel 66.The first part 60 includes a supply port 68 for receiving coolant 34 from the coolant supply line 44 and for directing the received coolant 34 into the internal supply flow channel 64, a removal port 70 for receiving coolant 34 from the internal removal flow channel 66 and for directing the received coolant 34 into the coolant return line 46, and releasable fastener engagement features 72 adjacent to the supply port 68 and the removal port 70 for receiving a releasable fastener, such as a threaded bolt, for attaching the respective coolant supply line 44 and the coolant return line 46. The releasable fastener 72 may be an opening and include a threaded insert that can be overmolded in the first part 60.The first portion 60 has an inner surface 73 facing the second portion 62 and includes a first rib 74 extending circumferentially, a second rib 76 extending adjacent the circumference within the first rib 74 and between the cavities 61 and 63, a third rib 78 surrounding the first cavity 61 within the second rib 76, and a fourth rib 80 surrounding the second cavity 63 within the second rib 76. As described below, the third and fourth ribs 78, 80 serve as rear stops for the seals 120.

[0023] The second part 62 includes inlets 82 that direct the received coolant 34 from the return ports 54 of the temperature control components 50 into the internal extraction flow channel 66, and outlets 84 that direct the coolant 34 from the internal supply flow channel 64 into the feed ports 52 of the temperature control components 50. With further reference to Fig. 12 and Fig. 13, the second part 62 includes attachment portions 86 with a fastener hole 88. The accumulator module 22 has a fastener engagement feature 89. The fastener engagement feature 89 may be a threaded hole. A releasable fastener 87, e.g., a threaded bolt, may attach the dual-function manifold 56 to the accumulator module 22 via the fastener engagement feature 89. The fastener holes 88 may include a compression limiter 90 through which the releasable fastener 87 is inserted. The compression limiter 90 limits the compression exerted on the attachment portion 86 when attached to the accumulator module 22. The compression limiter 90 may be overmolded in the attachment portion 86 or cold- or hot-pressed through the fastener hole 88.The mounting portions 86 may include an alignment hole 92 to accommodate the insertion of an alignment pin 94 on the battery module 22, as shown in FIG. Fig. 3, and to effect alignment of the dual-function manifold 56 with the accumulator module 22. Alignment should be possible by engagement with at least two alignment pins 94. The second portion 62 has an inner surface 95 facing the inner surface 73 of the first portion 60 and includes a rib 96 extending circumferentially adjacent the inlets 82 and the outlets 84 and between the inlets 82 and the outlets 84.

[0024] With reference to Fig. 2, Fig. 6A, Fig. 6B, Fig. 6C and Fig. 9, the single-function manifold 58 comprises a first part 98 and a second part 100. Each part 98, 100 is separately injection-molded and, as described above, may be made of a variety of materials, with the parts being joined together to form the single-function manifold 58. The first part 98 includes a cavity 101 which, when joined to the second part 100, forms an internal flow channel 102. The internal flow channel 102 serves either to receive coolant 34 from a coolant supply line 44 when part of a supply manifold 57, or to return coolant 34 to a coolant return line 46 when part of a withdrawal manifold 59.The first part 98 includes an access feature 104 providing access to the internal flow channel 102 and a releasable fastener engagement feature 72 adjacent to the access feature 104 for receiving a releasable fastener, e.g., a threaded bolt, for attaching the coolant supply line 44 when part of a supply manifold 57 or the coolant return line 46 when part of a withdrawal manifold 59. The access feature 104 serves as a supply port for receiving coolant 34 from the coolant supply line 44 and for directing the received coolant 34 into the inner flow channel 102 when it is part of a supply manifold 57, or as a withdrawal port for returning the coolant 34 from the inner flow channel 102 to the coolant return line 46 when it is part of a withdrawal manifold 59.The releasable fastener 72 may be an opening and include a threaded insert that may be overmolded within the first portion 98. The first portion 98 has an inner surface 106 facing the second portion 100 and includes a first rib 108 extending circumferentially, a second rib 110 extending adjacent the circumference within the first rib 108, and a third rib 112 surrounding the cavity 101 within the second rib 110. As described below, the third rib 112 serves as a rear stop for the seals 120.

[0025] The second part 100 includes engagement openings 114 that provide coolant flow paths between the internal flow channel 102 and the temperature control components 50 in an accumulator module 22. The engagement openings 114 serve as inlets that engage with the return ports 54 on a temperature control component 50 and direct the received coolant 34 from the return ports 54 into the internal flow channel 102 when they are part of a withdrawal manifold 59, or as outlets that engage with the feed ports 52 on a temperature control component 50 and direct the coolant 34 from the internal flow channel 102 into the feed ports 52 when they are part of a supply manifold 57. The second part 100 includes attachment portions 86 with a fastener hole 88 for receiving a releasable fastener, such asa threaded bolt to attach the single function manifold 58 to the battery module 22 via a releasable fastener engagement feature 89 on the battery module 22, such as a threaded receiving opening. The fastener holes 88 may include a compression limiter 90 through which the releasable fastener may extend and which limits the compression exerted on the attachment portion 86 when attached to the battery module 22. The compression limiters 90 may be overmolded into the attachment portions 86 and the fastener holes 88, or cold- or hot-pressed through the associated fastener holes 88. The attachment portions 86 may include an alignment hole 92 to accommodate the insertion of an alignment pin 94 on the battery module 22, as shown in FIG. Fig. 3, and to effect alignment of the single-function manifold 58 with the battery module 22. Alignment should be possible by engagement with at least two alignment pins 94. The second portion 100 has an inner surface 116 facing the inner surface 106 of the first portion 98 and includes a rib 118 extending circumferentially adjacent the engagement openings 114.

[0026] With reference to Fig. 5C, Fig. 6C, Fig. 8 and Fig. 9, the dual-function manifold 56 is formed by joining the first and second parts 60, 62, and the single-function manifold 58 is formed by joining the first and second parts 98, 100. The first and second parts 60, 62 and 98, 100 are aligned with each other and can be joined together in a variety of ways. As described below, the ribs on the parts engage each other to form the manifold 48. In the dual-function manifold 56, the second rib 76 on the first part 60 is aligned with the rib 96 on the second part 62. In the single-function manifold 58, the second rib 110 on the first part 98 is aligned with the rib 118 on the second part 100. The aligned ribs 76, 96 and 110, 118 can be joined together using friction welding, ultrasonic welding, laser welding, and an adhesive. Other joining methods may also be used.The interconnected ribs 76, 96 connect the first and second portions 60, 62 of the dual-function manifold 56 and form a seal around the internal supply and extraction flow channel 64, 66 to retain the coolant 34 therein. The interconnected ribs 110, 118 connect the first and second portions 98, 100 of the single-function manifold 58 and form a seal around the internal flow channel 102 to retain the coolant 34 therein. A gasket (not shown) could also be placed between the first and second portions 60, 62 and 98, 100 to provide additional sealing.

[0027] With reference to Fig. 7, Fig. 8, Fig. 9, Fig. 10 and Fig. 11, the distributors 48 include seals 120 that are integrated into the inlets 82 and the outlets 84 of the second part 62 of the dual-function distributors 56 and into the engagement openings 114 of the second part 100 of the single-function distributors 58. The seals 120 have an outer portion that seals against the inlets 82, the outlets 84, and the engagement openings 114, and an inner portion that is sealable against the feed ports 52 and the return ports 54. The inlets 82, the outlets 84, and the engagement openings 114 each have, as shown in Fig. 9, a generally cylindrical inner surface having a first portion 122 having a first inner diameter 124 and a second portion 126 having a second inner diameter 128 larger than the first inner diameter 124. The second portion 126 is adjacent to the first part. The larger second inner diameter 128 forms a counterbore with a step feature 130 between the first and second portions 122, 126. The seals 120 are made of a flexible material, such as ethylene propylene diene monomer rubber (EPDM), and seal against the associated manifold 48 and the feed ports 52 and return ports 54 of the associated temperature control components 50.The seals 120 have first and second opposite ends 133, 135 and a generally cylindrical exterior with a first portion 132 adjacent the first end 133 and having a first outer diameter 134, and a second portion 136 adjacent the second end 135 and having a second outer diameter 138 larger than the first outer diameter 134. The different outer diameters 134, 138 form an edge 140 on the seals 120 between the first and second portions 132, 136. The size of the second outer diameter 138 may vary along the second portion 136, with the largest portion adjacent the edge 140 and the smallest portion adjacent the second end 135.The seals 120 have a generally cylindrical interior extending from the second end 135 to the first end 133, and a flexible inner circular sealing wall 142 extending internally from the first end 133 to the second end 135 and having an end edge 144. The inner diameter of the sealing wall 142 decreases as it extends from the first end 133 to the end edge 144, and the end edge 144 has an inner diameter that is smaller than the outer diameter of the feed port 52 and the return port 54 of the temperature control component 50. The sealing wall 142 engages and seals against an inserted feed port 52 or return port 54 of a temperature control component 50, with the temperature control component passing through and sealing against the end edge 144. The seals 120 may include an inner rigid bushing to limit compression of the seal 120.

[0028] The seals 120 can be integrated into the associated manifold 48 either before or after joining the associated first and second sections 60, 62 and 98, 100 of the respective dual-function manifold 56 and the single-function manifold 58 by inserting the seals 120 into the inlets 82 and outlets 84 of the second part 62 of the dual-function manifold 56 and into the engagement openings 114 of the second part 100 of the single-function manifold 58. The third and fourth ribs 78, 80 of the first part 60 of the dual-function manifold 58 are aligned with the corresponding inlets 82 and outlets 84 of the second part 62 of the dual-function manifold 56.The third and fourth ribs 78, 80 form rear stops that can engage the second ends 135 of the seals 120 and limit movement of the seals 120 within the associated inlets 82 and outlets 84 toward the first portion 60 of the dual-function manifold 56. The third rib 112 of the first portion 98 of the single-function manifold 58 is aligned with the engagement openings 114 of the second portion 100 of the single-function manifold 58. The third rib 112 forms a rear stop that can engage the second ends 135 of the seals 120 and limit movement of the seals 120 within the engagement openings 114 toward the first portion 98 of the single-function manifold 58. The step feature 130 described below is a retention feature because it holds the seals 120 in the manifolds 48, 56, 57, 58, 59.The step feature 130 engages the edge 140 of the seal 120 and prevents the seal 120 from being removed from the outlets 84 and the inlets 82 away from the first portion 60 of the dual-function manifold 56, and allows the dual-function manifold 56 to be removed from the associated accumulator module 22 with the seals 120 remaining in the dual-function manifold 56. The step feature 130 engages the edge 140 of the seal 120 and prevents the seal 120 from being removed from the engagement openings 114 away from the first portion 98 of the single-function manifold 58, and allows the single-function manifold 58 to be removed from the associated accumulator module 22 with the seals 120 remaining in the single-function manifold 58.

[0029] With reference to Fig.2, the coolant supply lines 44 and the coolant return lines 46 include mounting clips 148 that allow the coolant supply lines 44 and the coolant return lines 46 to be removably attached to the manifolds 48. The mounting clips 148 include a mounting feature, such as a threaded stud or an opening that can receive a removably mounted fastener that aligns with the access feature 104 on the manifold 48 when the coolant supply lines 44 and the coolant return lines 46 are attached to the manifold 48. Connecting via mounting clips 148 instead of the normally used Society of Automotive Engineers (SAE) J2044 Quick Connectors reduces space requirements and increases robustness.

[0030] Forming the manifolds 48 with separately injection-molded parts, as described above, allows for easy incorporation of complex geometries and the inclusion of the features and functions described above that could not be created with a single injection-molded body. Because the manifolds 48 are detachable from the battery modules 22 and the seals 120 are retained, the rechargeable energy storage system 18 is enabled to be serviced, and problems with leaking seals can be corrected by replacing the associated manifold 48 without requiring the associated battery modules 22 to be taken out of service. Incorporating the seals 120 into the manifolds 48 rather than the temperature control components 50 allows for a simpler design of the control components 50 and eliminates the need to manufacture a serviceable control component 50 to repair a leaking seal 120.

[0031] The description of the present disclosure is merely exemplary, and variations that do not depart from the gist of the present disclosure are intended to be included within the scope of the present disclosure. Such variations should not be construed as a departure from the spirit and scope of the present disclosure.

Claims

[1] Cooling system manifold for an accumulator module (22), wherein the accumulator module (22) has at least one accumulator cell (32) and at least one temperature control component (50) having a flow path with a feed port (52) for receiving coolant (34) and a return port (54) for discharging coolant (34), the cooling system manifold comprising: a supply manifold (57) attachable to the accumulator module (22) for supplying coolant (34) to the at least one temperature control component (50) in the accumulator module (22), wherein the supply manifold (57) comprises a separately formed first part (98) of the supply manifold (57) connected to a second part (100) of the supply manifold (57) to form an internal supply channel, wherein the first part (98) of the supply manifold (57) comprises a supply nozzle (68) that directs the coolant (34) into the internal supply channel, wherein the second part (100) of the supply manifold (57) comprises an outlet that directs the coolant (34) from the internal supply channel to the feed nozzle (52), a first seal (120) arranged in the outlet, the first seal (120) having a first portion (132) sealed against the outlet and a second portion (136) sealable against the feed nozzle (52), a withdrawal manifold (59) attachable to the accumulator module (22) for withdrawing coolant (34) from the at least one temperature control component (50) in the accumulator module (22), wherein the withdrawal manifold (59) comprises a separately formed first portion (98) of the withdrawal manifold (59) connected to a second portion (100) of the withdrawal manifold (59) to form an internal withdrawal channel, wherein the first portion (98) of the withdrawal manifold (59) comprises a withdrawal port that directs coolant (34) from the internal withdrawal channel, and the second portion (100) of the withdrawal manifold (59) comprises an inlet that directs coolant (34) from the return port (54) to the internal withdrawal channel, and a second seal (120) disposed within the inlet, the second seal (120) having a first portion (132) sealed against the inlet and a second portion (136) sealable against the return port (54), wherein the first part (98) of the supply manifold (57) and the second part (100) of the supply manifold (57) are separately injection-molded and comprise connecting elements which connect the first part (98) of the supply manifold (57) to the second part (100) of the supply manifold (57) and form a seal which holds the coolant (34) in the inner supply channel, wherein the first seal (120) is arranged within the outlet either before or after the joining of the first part (98) of the supply manifold (57) and the second part (100) of the supply manifold (57), wherein the first part (98) of the extraction manifold (59) and the second part (100) of the extraction manifold (59) are separately injection-molded and comprise connecting elements which connect the first part (98) of the extraction manifold (59) to the second part (100) of the extraction distributor (59) and form a seal that holds the coolant (34) in the inner extraction channel,and wherein the second seal (120) is arranged within the inlet either before or after the first part (98) of the extraction manifold (59) and the second part (100) of the extraction manifold (59) are joined together, wherein the outlet comprises an inner surface, the outlet inner surface having a step feature (130) formed in the injection-molded part, the first portion (132) of the first seal (120) having an outer diameter that contacts the step feature (130) of the outlet and prevents removal of the first seal (120) from the outlet away from the first part (98) of the supply manifold (57) and allows the supply manifold (57) to be removed from the accumulator module (22), the first seal (120) remaining in the supply manifold (57), and the inlet has an inner surface, the inlet inner surface having a step feature (130) formed in the injection-molded part, the first portion (132) of the second seal (120) having an outer diameter,which contacts the step feature (130) of the inlet and prevents the removal of the second seal (120) from the inlet away from the first portion of the extraction manifold (59) and allows the extraction manifold (59) to be removed from the accumulator module (22) with the second seal (120) remaining in the extraction manifold (59). [2] Cooling system manifold according to claim 1, wherein the second part (100) of the supply manifold (57) has a plurality of attachment sections (86) and the attachment sections (86) of the second part (100) of the supply manifold (57) are attached to the accumulator module (22) with releasable fastening elements (87), and the second part (100) of the extraction manifold (59) has a plurality of attachment sections (86) and the attachment sections (86) of the second part (100) of the extraction manifold (59) are attached to the accumulator module (22) with releasable fastening elements (87). [3] The cooling system manifold of claim 2, further comprising compression limiters (90) disposed in the attachment portions (86) of the second part (100) of the supply manifold (57) and in the attachment portions (86) of the second part (100) of the extraction manifold (59), wherein the compression limiters (90) limit the compression of the attachment portions (86) of the supply manifold (57) by the releasable fasteners (87) attaching the supply manifold (57) to the accumulator module (22) and limit the compression of the attachment portions (86) of the extraction manifold (59) by the releasable fasteners (87) attaching the extraction manifold (59) to the accumulator module (22). [4] The cooling system manifold of claim 2, wherein the attachment portions (86) of the second part (100) of the supply manifold (57) have two alignment holes that receive the insertion of alignment pins (94) on the accumulator module (22) and align the supply manifold (57) with the accumulator module (22), and the attachment portions (86) of the second part (100) of the extraction manifold (59) have two alignment holes that receive the insertion of alignment pins (94) on the accumulator module (22) and align the extraction manifold (59) with the accumulator module (22). [5] Cooling system manifold according to claim 1, wherein a coolant supply line (44) with a supply attachment bracket supplies coolant (34) to the supply manifold (57), a coolant return line (46) with a return attachment bracket removes coolant (34) from the withdrawal manifold (59), the first part (98) of the supply manifold (57) has a releasable fastener engagement opening adjacent the supply nozzle (68), the first part (98) of the withdrawal manifold (59) has a releasable fastener engagement opening adjacent the withdrawal nozzle, the coolant supply line (44) is attached to the supply nozzle (68) with the supply attachment bracket, which is attached to the supply manifold (57) with a fastener (87) in the fastener engagement opening of the supply manifold (57), and the coolant return line (46) is attached to the withdrawal nozzle with the Return mounting bracket is attached,which is attached to the extraction distributor (59) with a fastening element (87) in the fastening element engagement opening of the extraction distributor (59). [6] The cooling system manifold of claim 1, wherein the first portion (98) of the supply manifold (57) includes a rear stop formed in the injection molded part and aligned with the outlet, the rear stop of the supply manifold (57) limiting movement of the first seal (120) in the outlet toward the first portion (98) of the supply manifold (57), the first portion (98) of the extraction manifold (59) includes a rear stop formed in the injection molded part and aligned with the inlet, the rear stop of the extraction manifold (59) limiting movement of the second seal (120) in the inlet toward the first portion (98) of the extraction manifold (59).

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