Cooling assembly for a battery pack

Abstract

Cooling arrangement for a battery pack with at least one cylindrical battery cell, comprising a distributor with an inlet line for receiving a coolant and an outlet line for expelling the coolant, a belt distributor connected to the distributor and having a supply line in fluid connection with the inlet line and a return line in fluid connection with the outlet line, comprising a belt in contact with the cylindrical battery cell and defining an outlet channel and a return channel, wherein the belt is connected to the belt distributor and the outlet channel is in fluid connection with the supply line and the return channel is in fluid connection with the return line, and a spacer plate arranged between the distributor and the belt distributor.The coolant flows from the distributor's inlet line to the tape head's supply line to the tape's outlet channel to cool the cylindrical battery cell, and the coolant flows from the outlet channel to the return channel and through the tape head's return line to the distributor's outlet line.

Description

Technical area

[0001] The present disclosure relates to a cooling assembly for a battery pack. In particular, the present disclosure relates to a cooling assembly for a belt-cooled battery pack. introduction

[0002] Electric and hybrid vehicles use a high-voltage electrical battery system consisting of several battery cells. These electric and hybrid vehicles typically require multiple battery cells to meet the vehicle's power and energy needs. The battery cells are often located under the vehicle body, midway between the front and rear wheels.

[0003] Battery cells, especially the high-voltage type described above, generate significant amounts of heat during continuous operation. Over time, the heat generated can compromise the efficiency and overall structural integrity of the battery pack. Therefore, thermal management systems are used to precisely regulate the temperature of the battery pack. In one type of thermal management system, the heat transfer fluid circulates to and from the fins or bands arranged between the battery cells. While this is effective, there is a need for improved coolant system designs. Description of the invention

[0004] A cooling assembly for a battery pack having at least one cylindrical battery cell is provided. The cooling assembly includes a manifold having an inlet conduit for receiving a coolant and an outlet conduit for expelling the coolant, a belt head connected to the manifold and having a belt supply conduit in fluid communication with the inlet conduit and a belt return conduit in fluid communication with the outlet conduit, and a belt in contact with the cylindrical battery cell and defining an exit channel and a return channel therethrough. The belt is connected to the belt head, and the exit channel is in fluid communication with the belt supply conduit and the return channel is in fluid communication with the belt return conduit. A spacer plate is disposed between the manifold and the belt head.The coolant flows from the inlet line of the distributor to the strip feed line of the strip head to the outlet channel of the strip to cool the cylindrical battery cell, and the coolant flows from the outlet channel to the return channel and through the strip return line of the strip head to the outlet line of the distributor.

[0005] In one aspect, the tape is connected to a front surface of the tape head.

[0006] In another aspect, the manifold is connected to the tape head by at least one mechanical fastener extending parallel to the front surface and through the spacer plate, thereby preventing forces from being transmitted to the tape during assembly of the manifold to the tape head.

[0007] In another aspect, the front surface has a slot defined by parallel flanges extending from the front surface, and a proximal end of the band is disposed within the slot.

[0008] In another aspect, a tape feed opening is arranged within the slot on the front surface and a tape return opening is arranged within the slot on the front surface, the tape feed opening being in communication with the tape feed line and the output channel of the tape and the tape return opening being in communication with the tape return line and the return channel of the tape.

[0009] In another aspect, a vertical feed line and a first connecting line are arranged within the strip head, wherein the vertical feed line communicates with the inlet line of the distributor and the first connecting line communicates between the vertical feed line and the strip feed line.

[0010] In another aspect, a vertical return line and a second connecting line are arranged within the belt head, wherein the vertical return line communicates with the outlet line of the distributor and the second connecting line extends between the vertical return line and the belt return line.

[0011] In another aspect, the manifold comprises a composite material.

[0012] In another aspect, the spacer plate comprises a frame having a plurality of windows and a seal disposed along an edge of the plurality of windows to seal the manifold to the tape head.

[0013] In another aspect, the inlet conduit comprises a supply opening extending to a bottom surface of the distributor, and the outlet conduit comprises a return opening extending to the bottom surface of the distributor, wherein the band distributor comprises a band distributor inlet and a band distributor outlet, each disposed in an upper surface of the band distributor, the band distributor inlet being in fluid communication with the supply opening and the band supply conduit, and the band distributor outlet being in fluid communication with the return opening and the band return conduit.

[0014] In another aspect, one of the plurality of windows in the spacer plate is aligned with the feed opening and the inlet of the tape head, and another of the plurality of windows is aligned with the return opening and the outlet of the tape head.

[0015] In another embodiment, a battery pack is provided. The battery pack includes a battery tray, a plurality of cylindrical battery cells supported on the battery tray, and a cooling assembly.The cooling assembly includes a manifold having an inlet conduit for receiving a coolant and an outlet conduit for expelling the coolant, the inlet conduit having a plurality of supply openings extending to a bottom surface of the manifold, and the outlet conduit having a plurality of return openings extending to the bottom surface of the manifold, a plurality of tape heads each connected to the bottom surface of the manifold and each having a tape supply conduit in fluid communication with one of the supply openings and a tape return conduit in fluid communication with one of the return openings, and a plurality of tapes in contact with the plurality of cylindrical battery cells and each defining an outlet channel and a return channel therethrough.Each of the plurality of belts is connected to a corresponding one of the plurality of belt heads, and each of the output channels is in fluid communication with the belt supply line of the corresponding one of the plurality of belt heads, and each of the return channels is in fluid communication with the belt return line of the corresponding one of the plurality of belt heads. A spacer plate is disposed between the manifold and the plurality of belt manifolds, the spacer plate being configured to seal the manifold from the plurality of belt manifolds.The coolant flows from the inlet line of the distributor to the strip feed lines of the plurality of strip distributors via the feed openings, and for each of the plurality of strip distributors, the coolant flows to the output channel of the respective one of the plurality of strips to cool the cylindrical battery cell, and the coolant flows from the output channel to the return channel and through the strip return lines of the plurality of strip distributors to the outlet line of the distributor via the return openings.

[0016] In one aspect, each of the plurality of tapes is connected to a front surface of the respective one of the plurality of tape heads.

[0017] In another aspect, the distributor is connected to the plurality of tape heads by a plurality of mechanical fasteners each extending parallel to the front surfaces and through the spacer plate, thereby preventing forces from being transmitted to the plurality of tapes during assembly of the distributor to the plurality of tape heads.

[0018] In another aspect, each of the front surfaces has a slot defined by parallel flanges extending from the front surface, and a proximal end of one of the plurality of bands is disposed within each of the slots.

[0019] In another aspect, a tape feed opening is disposed within the slot on the front surface and a tape return opening is disposed with the slot on the front surface, the tape feed opening being in communication with the tape feed line and the output channel of one of the plurality of tapes and the tape return opening being in communication with the tape return line and the return channel of one of the plurality of tapes.

[0020] In another aspect, a vertical feed line and a first connecting line are arranged in each of the plurality of tape heads, wherein the vertical feed line communicates with the inlet line of the distributor and the first connecting line communicates between the vertical feed line and the tape feed line.

[0021] In another aspect, a vertical return line and a second connecting line are arranged in each of the plurality of tape heads, the vertical return line communicating with the outlet line of the distributor and the second connecting line extending between the vertical return line and the tape return line.

[0022] In another aspect, the manifold comprises a composite material.

[0023] A battery thermal management system for a cylindrical battery cell is provided. The battery thermal management system includes a recovery tank that stores a coolant, a pump in fluid communication with the recovery tank to pump the coolant, and a cooling assembly.The cooling assembly includes a manifold having an inlet conduit in fluid communication with the pump to receive the coolant and an outlet conduit to discharge the coolant, a band manifold connected to the manifold and having a supply conduit in fluid communication with the inlet conduit and a return conduit in fluid communication with the outlet conduit, a band in contact with the cylindrical battery cell and defining an outlet channel and a return channel therethrough, the band being connected to the band head, the outlet channel being in fluid communication with the supply conduit and the return channel being in fluid communication with the return conduit, a spacer plate disposed between the manifold and the band head, and a heat exchanger in fluid communication with the outlet conduit of the manifold and the recovery tank.The coolant is pumped by the pump to the inlet line of the manifold, the coolant flows from the inlet line of the manifold to the supply line of the belt head to the outlet channel of the belt to cool the cylindrical battery cell, and the coolant flows from the outlet channel to the return channel and through the return line of the belt head to the outlet line of the manifold and from the outlet line to the heat exchanger and then to the recovery tank.

[0024] Further areas of applicability will become apparent from the present description. It should be understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. Brief description of the drawings

[0025] 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 is a schematic view of an exemplary motor vehicle having a battery pack with a cooling assembly in accordance with the principles of the present disclosure; Fig. 2 is a top perspective view of the cooling assembly; Fig. 3 is an exploded perspective view of the cooling assembly from above; Fig. 4 is a cross-sectional view of the cooling assembly in the direction of arrows 4-4 in Fig. 2; Fig. 5 is a cross-sectional view of the cooling assembly in the direction of arrows 5-5 in Fig. 2 seen; Fig. 6 is a cross-sectional view of the cooling assembly in the direction of arrows 6-6 in Fig. 2 seen; Fig. 7 is a cross-sectional view of the cooling assembly in the direction of arrows 7-7 in Fig. 2; and Fig. Figure 8 is a top perspective view of a spacer plate in the cooling assembly. Detailed description

[0026] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0027] With reference to Fig. 1, a cooling assembly 10 for a battery pack 12 is shown in accordance with the principles of the present disclosure. The cooling assembly 10 is configured to cool the battery pack 12, as described in more detail below. The battery pack 12 is illustrated with an exemplary vehicle 14. The vehicle 14 is preferably an electric vehicle or a hybrid vehicle having wheels 16 driven by electric motors / inverters 18. The electric motors / inverters 18 are supplied with motive power by the battery 12. Although the vehicle 14 is illustrated as a road vehicle, the cooling assembly 10 and battery pack 12 may also be used for various other types of vehicles. For example, the cooling assembly 10 and battery pack 12 may be used in watercraft, such as boats, or in aircraft, such as drones or passenger aircraft.In addition, the cooling assembly 10 and the battery pack 12 can be used as a stationary energy source separately and independently of a vehicle.

[0028] The battery pack 12 generally includes a battery tray 20 connected to the vehicle 14. The battery tray 20 provides structural support to one or more battery cells 22 (only one of which is shown) disposed within the battery pack 12. The battery cells 22 are preferably cylindrical lithium-ion battery cells. However, any type of battery cell 22 may be used as long as the battery cell 22 is compatible with the cooling assembly 10.

[0029] Now with reference to the Fig. 2 and Fig. 3, the cooling assembly 10 is illustrated with respect to one of the battery cells 22. The cooling assembly 10 is configured to circulate a coolant 24 therethrough to cool the battery cells 22 through heat transfer. The cooling assembly 10 is part of a larger battery thermal management system 26, which generally includes a pump 28, a heat exchanger 30, and a recovery tank 32. The battery thermal management system 26 may include various other components, including temperature and humidity sensors, valves, and electronic controls, without departing from the scope of the present disclosure. Generally, the pump 28 is in fluid communication with the recovery tank 32 and pumps the coolant 24 from the recovery tank 32 into the cooling assembly 10. The cooling assembly 10 directs the coolant 24 to the battery cells 22 to cool them.The coolant 24 is then returned from the cooling assembly 10 and passed to the heat exchanger 30. The heat exchanger 30 extracts heat from the coolant 24, e.g., through a liquid-to-air heat exchanger with a fan, although other types of heat exchangers may also be used. The coolant 24 is returned to the recovery tank 32.

[0030] The cooling assembly 10 includes a manifold 40, one or more tape heads 42, one or more tapes 44, and a spacer plate 46. The manifold 40 is connected to the tape heads 42 via one or more mechanical fasteners 48. The tapes 44 are each individually connected to one of the tape heads 42. The spacer plate 46 is disposed between the manifold 40 and the tape heads 42. Each of these components is described in more detail below.

[0031] The manifold 40 is configured to direct the coolant 24 received from the pump 28 to each of the belt heads 42. The manifold is made of a composite material, such as glass-filled nylon. Other composite materials may also be used, selected to reduce weight and be compatible with the coolant 24. The manifold 40 includes an inlet 50 and an outlet 52 disposed in one end 54 of the manifold 40. The inlet 50 communicates with an inlet line 56 ( Fig. 4), which extends over the entire length of the distributor 40. The outlet 52 is connected to an outlet line 58 ( Fig. 6) extending the entire length of the manifold 40. The inlet line 56 and the outlet line 58 are preferably through holes drilled into the manifold and run parallel to each other. An end 60 of the inlet line 56 opposite the inlet 50 and an end 62 of the outlet line 58 opposite the outlet 52 can each be connected to additional pumps, heat exchangers, and recovery tanks or closed with plugs 64.

[0032] As in Fig. 4, the inlet line 56 includes one or more feed openings 66 extending to a bottom surface 68 of the distributor 40. The number of feed openings 66 corresponds to the number of belt heads 42 and the number of belts 44. In the present example, there are therefore four feed openings 66. However, it should be noted that one or more belt heads 42 and belts 44 may be used.

[0033] As in Fig. 6, the outlet line 58 includes one or more return ports 70 extending to the bottom surface 68 of the distributor 40. The number of return ports 70 corresponds to the number of belt heads 42 and the number of belts 44.

[0034] Again with reference to Fig. 3, the belt heads 42 are configured to direct the coolant 24 received from the manifold 40 to a corresponding belt 44. The belt heads 42 are connected to the manifold 40 at the bottom 68 of the manifold 40. The belt heads 42 are identical and will therefore only be described individually. The belt head 42 is preferably made of a die-cast metal. The belt head 42 includes a belt head inlet 72 disposed on an upper surface 74 of the belt head 42. The belt head inlet 72 is in fluid communication with the supply opening 66 of the manifold 40 for receiving the coolant 24. A belt head outlet 76 is disposed on the top surface 74 of the belt head 42. The belt head outlet 76 is in fluid communication with the return opening 70 of the manifold 40 for directing the coolant 24 back to the manifold 40.

[0035] With reference to the Fig. 5 and Fig. 7, the belt head inlet 72 is connected to a vertical feed line 78, which extends over the entire height (in the Z direction) of the belt head 42. The belt head outlet 76 is connected to a vertical return line 80 ( Fig. 6) in connection, which extends over the height (in Z-direction, as in Fig. 1 and Fig. 3) of the tape head 42. The vertical supply line 78 and the vertical return line 80 are preferably through holes drilled into the tape head 42 and running parallel to each other.

[0036] The tape head 42 further comprises a tape feed line 82 ( Fig. 5) and a belt return line 84 ( Fig. 7). Both the tape supply line 82 and the tape return line 84 are arranged between the vertical supply line 78 and the vertical return line 80. The tape supply line 82 is connected to the vertical return line 80 via a first connecting line 86 ( Fig. 5) is connected to the vertical feed line 78. The first connecting line 86 is a through-hole drilled into one side 88 of the tape head 42 and leads through the vertical feed line 78 to the tape feed line 82. One of the plugs 64 is arranged in one end of the first connecting line 86 to seal the first connecting line 86 from the external environment. Likewise, the tape return line 84 is connected to the vertical return line 80 via a second connecting line 90 ( Fig. 7). The second connecting line 90 is a through-hole drilled into one side 92 of the tape head 42 and leading through the vertical return line 80 to the tape return line 84. One of the plugs 64 is disposed in one end of the second connecting line 90 to seal the second connecting line 90 from the external environment.

[0037] The tape feed line 82 is connected to a tape feed opening 96 ( Fig. 5) located on a front surface 98 of the tape head 42. The tape return line 84 communicates with a tape return port 100 located on the front surface 98. Both the tape feed port 96 and the tape return port 100 are located in a slot 102 formed by parallel flanges 104 extending from the front surface 98. The slot 102 is sized to accommodate the tape 44.

[0038] With further reference to the Fig. 5 and Fig. 7, the band 44 is configured to circulate the coolant 24 to the battery cells 22 to transfer heat from the battery cells 22 to the coolant 24. The band 44 is preferably made of aluminum and has an elongated, undulating shape that corresponds to the outer surface of the battery cells 22 (see Fig. 2). The band 44 is bifurcated along its length, with an exit channel 106 disposed therein and located below a separate return channel 108 disposed therein. The exit channel 106 communicates with the return channel 108 at a distal end (not shown) of the band 44. In this way, the coolant 24 can flow the entire length of the band 44 through the exit channel 106 to the distal end and return via the return channel 108 along the entire length of the band 44. The battery cell 22, in contact with the band 44, exchanges heat with the coolant 24 as it travels through the band 44. A proximal end 109 of the band 44 is disposed in the slot 102 of the band head 42 such that the output channel 106 communicates with the band feed opening 96 and the return channel 108 communicates with the band return opening 100. The band 44 is preferably welded to the band head 42.

[0039] Now with reference to Fig. 8, the spacer plate 46 is configured to seal the manifold 40 to the tape heads 42. The spacer plate 46 includes a frame 110. The frame 110 is preferably made of metal, for example, steel. Disposed within the frame 110 are a plurality of windows 112. The windows 112 are aligned with the inlets 72 and outlets 76 of the tape heads, as well as the feed ports 66 and return ports 70 of the manifold 40. In one aspect, the windows 112 are larger than the tape head inlets 72, the tape head outlets 76, the feed ports 66, and the return ports 70 to allow for easier alignment during assembly. A plurality of seals 114 are connected to the frame 110 around the edges of the windows 112. The seals 114 seal the feed openings 66 and the inlets of the tape head 72 from the return openings 70 and the outlets of the tape head 76.The seals 114 may be paper seals, edge-bonded seals, or room temperature vulcanizing (RTV) seals.

[0040] With combined reference to the Fig. 2-8, during operation, the coolant 24 is pumped by the pump 28 into the inlet line 56 of the manifold 40. The coolant 24 is then directed to each of the belt heads 42 via the feed openings 66. Within a particular belt head 42, the coolant 24 is received in the vertical feed line 78, directed through the first connecting line 86 to the belt feed line 82, and then on to the belt 44. The coolant 24 flows through the belt 44 in the exit channel 106 to the battery cells 22 and back via the return channel 108. The battery cells 22, which are in contact with the belt 44, exchange heat with the coolant 24 as they travel through the belt 44. The coolant 24 is returned to the belt return line 84 and directed via the second connecting line 90 to the vertical return line 80. The coolant 24 is then connected to the outlet line 58 of the distributor 40 via the return openings 70.The coolant 24 is then passed to the heat exchanger 30 and returned to the recovery tank 32.

[0041] Again with reference to the Fig.2-3, the cooling assembly 10 is assembled in the Z-direction using mechanical fasteners 48 to secure the manifold 40 to the tape heads 42. The mechanical fasteners 48 are arranged parallel to the front surface 98 of the tape head 42 and perpendicular to the bottom surface 68 of the manifold 40 and the top surface 74 of the tape head 42. Therefore, any forces applied during assembly act in the Z-direction (i.e., in the vertical direction relative to the vehicle 14 and the battery pack 12), and these forces are not transmitted to the tapes 44, thereby minimizing misalignment or offset of the tapes during manufacture of the cooling assembly 10. The arrangement of the manifold 40, the tape heads 42, the tapes 44, the spacer plate 46, and the specific arrangement of the fluid lines and channels simplifies assembly and improves the flow of the coolant 24 compared to the prior art.The cooling assembly 10 of the present disclosure also allows for easier maintenance of the seal of the spacer plate 46 and the use of a torque indicator on the mechanical fasteners 48 for error protection.

[0042] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be considered a departure from the spirit and scope of the present disclosure.

Claims

[1] A cooling assembly for a battery pack, the battery pack having at least one cylindrical battery cell, and the cooling assembly comprising: a manifold having an inlet conduit for receiving a coolant and an outlet conduit for expelling the coolant; a tape head connected to the manifold and having a tape supply line in fluid communication with the inlet line and a tape return line in fluid communication with the outlet line; a belt in contact with the cylindrical battery cell and defining an exit channel and a return channel, the belt being connected to the belt head, the exit channel being in fluid communication with the belt supply line and the return channel being in fluid communication with the belt return line; and a spacer plate disposed between the manifold and the strip head, wherein the coolant flows from the inlet conduit of the manifold to the strip feed conduit of the strip head to the strip exit channel to cool the cylindrical battery cell, and the coolant flows from the outlet channel to the return channel and through the strip return conduit of the strip head to the outlet conduit of the manifold. [2] The cooling assembly of claim 1, wherein the tape is connected to a front surface of the tape head. [3] The cooling assembly of claim 2, wherein the manifold is connected to the tape head by at least one mechanical fastener extending parallel to the front surface and through the spacer plate, thereby preventing forces from being transmitted to the tape during assembly of the manifold to the tape head. [4] The cooling assembly of claim 3, wherein the front surface includes a slot defined by parallel flanges extending from the front surface, and a proximal end of the band is disposed within the slot. [5] The cooling assembly of claim 4, further comprising a tape feed port disposed in the slot on the front surface and a tape return port disposed in the slot on the front surface, wherein the tape feed port communicates with the tape feed line and the output channel of the tape, and the tape return port communicates with the tape return line and the return channel of the tape. [6] The cooling assembly of claim 4, further comprising a vertical supply line and a first connecting line disposed in the belt head, the vertical supply line communicating with the inlet line of the manifold, and the first connecting line extending between the vertical supply line and the belt supply line. [7] The cooling assembly of claim 6, further comprising a vertical return line and a second connecting line disposed in the belt head, the vertical return line communicating with the outlet line of the manifold, and the second connecting line extending between the vertical return line and the belt return line. [8] The cooling assembly of claim 1, wherein the manifold comprises a composite material. [9] The cooling assembly of claim 1, wherein the spacer plate comprises a frame having a plurality of windows and a seal disposed along an edge of the plurality of windows to seal the manifold to the tape head. [10] The cooling assembly of claim 9, wherein the inlet conduit comprises a supply opening extending to a bottom surface of the manifold, and the outlet conduit comprises a return opening extending to the bottom surface of the manifold, wherein the band manifold comprises a band manifold inlet and a band manifold outlet, each disposed in an upper surface of the band manifold, the band manifold inlet being in fluid communication with the supply opening and the band supply conduit, and the band manifold outlet being in fluid communication with the return opening and the band return conduit.

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