RECHARGEABLE ENERGY STORAGE SYSTEM (RESS) WITH A COOLING PLATE WITH INTEGRATED VENT

Abstract

A battery assembly includes a housing having a bottom wall and a plurality of side walls that collectively define an interior space. A plurality of battery cells are disposed within the interior space. A heat exchange element is disposed between the bottom wall and the plurality of battery cells. The heat exchange element includes a plurality of cooling fluid channels that conduct a cooling fluid into heat exchange contact with the plurality of battery cells and a plurality of vent gas channels in fluid communication with the plurality of battery cells.

Description

INTRODUCTION

[0001] The present disclosure relates to vehicles and, more particularly, to a rechargeable energy storage system (RESS) having a cold plate with integrated venting.

[0002] Many newer vehicles are manufactured with electric propulsion systems. The electric propulsion system, whether all-electric or hybrid, relies on an electric motor powered by energy stored in a rechargeable energy storage system (RESS) or battery. During operation, the battery generates heat. This heat impairs the battery's efficiency. To reduce the heat generated by the battery, many vehicles include a cooling system that circulates a cooling fluid that is in thermal contact with the battery.

[0003] In some cases, the cooling system comprises a plate arranged within a battery enclosure. The battery cells rest on the plate. A cooling fluid flows through the plate, maintaining a heat-exchange relationship with the battery cells. In addition to cooling, battery assemblies include a venting system that directs gases out of the battery enclosure. Gases generated within the battery cells are channeled through ducts that exit the enclosure. Battery cells, cooling, venting, and power control systems occupy a significant amount of space within a battery assembly. The need to incorporate additional systems into the vehicle requires a reduction in component footprint. Accordingly, it is desirable to integrate components to create space to accommodate additional systems. SUMMARY

[0004] According to one non-limiting example, a battery assembly includes a housing having a bottom wall and a plurality of side walls that collectively define an interior space. A plurality of battery cells are disposed within the interior space. A heat exchange element is disposed between the bottom wall and the plurality of battery cells. The heat exchange element includes a plurality of cooling fluid channels that conduct a cooling fluid into heat exchange contact with the plurality of battery cells and a plurality of vent gas channels in fluid communication with the plurality of battery cells.

[0005] In addition to one or more of the features described herein, each of the plurality of cooling fluid channels includes a first end, a second end, and an intermediate portion, the plurality of cooling fluid channels extending along an axis of the heat exchanger element.

[0006] In addition to one or more of the features described herein, each of the plurality of vent gas channels includes a first end portion, a second end portion, and an intermediate portion, the plurality of vent gas channels extending along the axis of the heat exchanger element.

[0007] In addition to one or more of the features described herein, each of the plurality of vent gas channels is disposed between adjacent channels of the plurality of cooling fluid channels.

[0008] In addition to one or more of the features described herein, a blocking element extends across the heat exchanger element substantially perpendicular to the plurality of cooling fluid channels and the plurality of vent gas channels, the blocking element comprising a first end segment, a second end segment, and an intermediate segment closing the second end portion of each of the plurality of vent gas channels.

[0009] In addition to one or more of the features described herein, the barrier element includes an internal flow channel fluidly connecting the second end of each of the plurality of cooling fluid channels.

[0010] In addition to one or more of the features described herein, a cooling fluid inlet is fluidly connected to one of the plurality of cooling fluid channels and the first end of the blocking element, and a cooling fluid outlet is fluidly connected to another of the plurality of cooling fluid channels and the second end of the blocking element.

[0011] In addition to one or more of the features described herein, a vent gas collection element extends across the heat exchange element substantially perpendicular to the plurality of cooling fluid channels and the plurality of vent gas channels, the vent gas collection element fluidly connecting the first end portion of each of the plurality of vent gas channels to a sensor housing.

[0012] In addition to one or more of the features described herein, the vent gas collection element comprises a vent gas collection channel having a first channel portion extending across the heat exchange element, a second channel portion extending along the axis, and a third channel portion extending across the heat exchange element, the third channel portion comprising a sensor housing.

[0013] In addition to one or more of the features described herein, the vent gas collection element includes an internal cooling fluid channel fluidly connecting each of the plurality of cooling fluid channels.

[0014] A vehicle, according to one non-limiting example, includes a body, a plurality of wheels connected to the body, an electric drive unit supported within the body and operatively connected to at least one of the plurality of wheels, and a battery assembly operatively connected to the electric drive unit. The battery assembly includes a housing having a bottom wall and a plurality of side walls that collectively define an interior. A plurality of battery cells are disposed within the interior. A heat exchange element is disposed between the bottom wall and the plurality of battery cells. The heat exchange element includes a plurality of cooling fluid channels that direct a cooling fluid into heat exchange contact with the plurality of battery cells and a plurality of vent gas channels in fluid communication with the plurality of battery cells.

[0015] In addition to one or more of the features described herein, each of the plurality of cooling fluid channels includes a first end, a second end, and an intermediate portion, the plurality of cooling fluid channels extending along an axis of the heat exchanger element.

[0016] In addition to one or more of the features described herein, each of the plurality of vent gas channels includes a first end portion, a second end portion, and an intermediate portion, the plurality of vent gas channels extending along the axis of the heat exchanger element.

[0017] In addition to one or more of the features described herein, each of the plurality of vent gas channels is disposed between adjacent channels of the plurality of cooling fluid channels.

[0018] In addition to one or more of the features described herein, a blocking element extends across the heat exchanger element substantially perpendicular to the plurality of cooling fluid channels and the plurality of vent gas channels, the blocking element comprising a first end segment, a second end segment, and an intermediate segment closing the second end portion of each of the plurality of vent gas channels.

[0019] In addition to one or more of the features described herein, the barrier element includes an internal flow channel fluidly connecting the second end of each of the plurality of cooling fluid channels.

[0020] In addition to one or more of the features described herein, a cooling fluid inlet is fluidly connected to one of the plurality of cooling fluid channels and the first end of the blocking element, and a cooling fluid outlet is fluidly connected to another of the plurality of cooling fluid channels and the second end of the blocking element.

[0021] In addition to one or more of the features described herein, a vent gas collection element extends across the heat exchange element substantially perpendicular to the plurality of cooling fluid channels and the plurality of vent gas channels, the vent gas collection element fluidly connecting the first end portion of each of the plurality of vent gas channels to a sensor housing.

[0022] In addition to one or more of the features described herein, the vent gas collection element comprises a vent gas collection channel having a first channel portion extending across the heat exchange element, a second channel portion extending along the axis, and a third channel portion extending across the heat exchange element, the third channel portion comprising a sensor housing.

[0023] In addition to one or more of the features described herein, the vent gas collection element includes an internal cooling fluid channel fluidly connecting each of the plurality of cooling fluid channels.

[0024] The above features and advantages, as well as other features and advantages of the disclosure, will be readily apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Further features, advantages and details are included by way of example only in the following detailed description, which refers to the drawings in which: Fig. 1 is a left side view of a vehicle having a rechargeable energy storage system (RESS) with a cold plate with integrated venting according to a non-limiting example; Fig. 2 is a partial perspective view of a battery assembly having a cooling plate with integrated venting according to a non-limiting example; Fig. 3 a top view of the cooling plate with integrated ventilation from Fig. 2 according to a non-limiting example; Fig. 4 is a perspective cross-sectional view of the cooling plate with integrated venting supporting battery cells, according to a non-limiting example; Fig. 5 is a rear perspective view showing a locking element attached to the cooling plate, according to a non-limiting example; Fig. 6 is a front perspective view showing a vent gas collection element attached to the cooling plate, according to a non-limiting example; Fig. 7 is a top right perspective view of the cooling plate and the locking element according to a non-limiting example; and Fig. 8 is a plan view of the vent gas collection element according to a non-limiting example. DETAILED DESCRIPTION

[0026] The following description is merely exemplary and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference characters designate like or corresponding parts and features.

[0027] A vehicle according to a non-limiting example is in Fig. 1, generally designated 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20 having seats disposed behind an instrument panel 26. A steering controller 30 is disposed between the seats 23 and the instrument panel 26. The steering controller 30 is actuated to control the orientation of selected ones of the plurality of wheels 16. The vehicle 10 includes an electric drive unit 34 that drives one or more of the plurality of wheels 16.

[0028] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed within the housing 12 and provides power to the electric drive unit 34. In other arrangements, a fuel cell (not shown) may be used to power the electric drive unit 34. It should be noted that the position of the electric drive unit 34 and the battery assembly 38 may vary. As shown in Fig. 2, the battery assembly 38 includes a housing 50 having a bottom wall 52 and a plurality of side walls 54 that collectively define an interior region 58. The plurality of side walls 54 includes a first side wall 60, a second side wall 61, a third side wall 62, and a fourth side wall 63. A plurality of battery cells 68 are disposed within the interior region 58 of the housing 50.

[0029] In one non-limiting example, a heat exchanger element or cold plate 80 supports the plurality of battery cells 68 on the floor 52. Referring to Fig. 3 and Fig. 4, the cooling plate 80 includes a first surface 86 and a second surface 88 opposite the first surface 86. The first surface 86 and the second surface 88 are bounded by a first edge 90, a second edge 92, a first side edge 94, and a second side edge 96. An axis "A" of the cooling plate 80 extends between the first edge 90 and the second edge 92.

[0030] In one non-limiting example, the cold plate 80 includes a plurality of cooling fluid channels, one of which is designated 102 and extends between the first surface 86 and the second surface 88 substantially parallel to the axis "A." The plurality of cooling fluid channels 102 includes a cooling fluid inlet 104 located adjacent the first edge 90 at the first side edge 94 and a cooling fluid outlet 106 located adjacent the first edge 90 at the second side edge 96. The respective locations of the cooling fluid inlet 104 and the cooling fluid outlet 106 may vary. Each of the plurality of cooling fluid channels 102 defines closed conduits that carry a heat-absorbing fluid in heat exchange relationship with the plurality of battery cells 68.The cooling fluid channels 102 include a first end 110 at the first edge 90, a second end 112 at the second edge 92, and an intermediate portion 114 extending between the first end 110 and the second end 112. In the illustrated embodiment, the cooling fluid channels 102 are spaced apart from one another.

[0031] In one non-limiting example, in addition to the cooling fluid channels 102, the cold plate 80 includes a plurality of gas vent channels 120 extending between the first edge 90 and the second edge 92 substantially parallel to the axis "A." The gas vent channels 120 are in the form of recesses in the first surface 86. In one non-limiting example, each of the gas vent channels 120 includes a first end portion 130 located proximate the first edge 90, a second end portion 132 located proximate the second edge 92, and an intermediate portion 134 extending between the first end portion 130 and the second end portion 132. In one non-limiting example, the second end portion 130 is closed by a blocking member 140.

[0032] In one non-limiting example, the locking element 140 extends as in Fig. 3 and Fig. 5, across the first surface 86 between the first side edge 94 and the second side edge 96 at the second edge 92. The blocking element 140 includes a first end segment 144 disposed at the first side edge 94, a second end segment 146 disposed at the second side edge 96, and an intermediate segment 148 extending between the first end segment 144 and the second end segment 146. An internal flow channel 150, fluidly connected to each of the plurality of cooling fluid channels 102 at the second end 112, extends through the intermediate segment 148. The internal flow channel 150 promotes the circulation of cooling fluid, such as water, through the cooling fluid channels 102 between the cooling fluid inlet 104 and the cooling fluid outlet 106.

[0033] In one non-limiting example, the blocking member 140 also includes a plurality of blocking members 155 that close the second end portion 132 of each of the plurality of gas vent channels 120. In this way, gas that may escape from one or more of the plurality of battery cells 68 is prevented from exiting the second end portion 132 and is thus forced to flow to the first end portion 130 where it may be collected and captured.

[0034] In one non-limiting example, the cooling plate 80 includes a vent gas collection element 160 disposed over the first edge 90 on the first surface 86, as shown in Fig. 3, Fig. 6, Fig. 7 and Fig. 8. The vent gas collection element 160 includes a first edge portion 164 disposed at the first side edge 94 and a second edge portion 166 disposed at the second side edge 96. The vent gas collection element 160 includes an internal cooling fluid channel 168 fluidly connected to each of the plurality of cooling fluid channels 102 and a vent gas collection channel 170 extending between the first edge portion 164 and the second edge portion 166. The vent gas collection channel 170 includes a first channel portion 172 having a plurality of gas inlets 174 fluidly connected to each of the plurality of vent gas channels 120. The first channel portion 172 extends along the first edge 90 substantially perpendicular to the axis "A."

[0035] In a non-limiting example, Fig.8, a second channel portion 176 extends from the first channel portion 172 adjacent the first side edge 94. The second channel portion 176 extends substantially parallel to the axis "A." The vent gas collection channel 169 further includes a third channel portion 178 fluidly connected to the second vent gas channel portion 172 and extending therefrom to the second side edge 96. The third vent channel portion 178 extends substantially perpendicular to the axis "A." A sensor housing or gas collection chamber 182 is fluidly connected to the third channel portion 178 at the second edge 92. The sensor housing 182 may support a sensor (not shown) that detects gases exiting the plurality of battery cells 68.The geometry of the vent gas collection channel 170 ensures that the gases exiting the multiple vent gas channels 120 have the opportunity to cool before being collected.

[0036] The terms "a" and "an" do not imply a limitation of quantity, but denote the presence of at least one of the stated elements. The term "or" means "and / or" unless the context clearly indicates otherwise. When reference is made throughout this specification to "an aspect," this means that a particular element (e.g., a feature, structure, step, or property) described in connection with the aspect is included in at least one of the aspects described in this specification and may or may not be present in other aspects. It is understood that the described elements in the various aspects may be combined in any suitable manner.

[0037] When an element such as a layer, film, region, or substrate is described as lying "on" another element, it may lie directly on top of the other element, or there may be intervening elements. In contrast, when an element is described as lying "directly on" another element, there are no intervening elements.

[0038] Unless otherwise indicated herein, all examination standards are the most recent standard in force on the filing date of this application or, if priority is claimed, on the filing date of the earliest priority application in which the examination standard appears.

[0039] Unless otherwise defined, technical and scientific terms used in this document have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0040] Although the above disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made and equivalent elements may be substituted without departing from the scope thereof. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from its essential scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within its scope.

Claims

[1] Battery assembly comprising: an enclosure having a bottom wall and a plurality of side walls that together define an interior space; a plurality of battery cells arranged in the interior; and a heat exchanger element disposed between the bottom wall and the plurality of battery cells, the heat exchanger element comprising a plurality of cooling fluid channels directing a cooling fluid into heat exchange contact with the plurality of battery cells and a plurality of vent gas channels in fluid communication with the plurality of battery cells. [2] The battery assembly of claim 1, wherein each of the plurality of cooling fluid channels includes a first end, a second end, and an intermediate portion, the plurality of cooling fluid channels extending along an axis of the heat exchanger element. [3] The battery assembly of claim 2, wherein each of the plurality of vent gas channels comprises a first end portion, a second end portion, and an intermediate portion, the plurality of vent gas channels extending along the axis of the heat exchanger element. [4] The battery assembly of claim 3, wherein each of the plurality of vent gas channels is disposed between adjacent ones of the plurality of cooling fluid channels. [5] The battery assembly of claim 3, further comprising a blocking member extending across the heat exchanger member substantially perpendicular to the plurality of cooling fluid channels and the plurality of vent gas channels, the blocking member comprising a first end segment, a second end segment, and an intermediate segment closing the second end portion of each of the plurality of vent gas channels. [6] The battery assembly of claim 5, wherein the blocking member comprises an internal flow channel fluidly connecting the second end of each of the plurality of cooling fluid channels. [7] The battery assembly of claim 5, further comprising a cooling fluid inlet fluidly connected to one of the plurality of cooling fluid channels and the first end of the blocking member, and a cooling fluid outlet fluidly connected to another of the plurality of cooling fluid channels and the second end of the blocking member. [8] The battery assembly of claim 5, further comprising a vent gas collection member extending across the heat exchange member substantially perpendicular to the plurality of cooling fluid channels and the plurality of vent gas channels, the vent gas collection member fluidly connecting the first end portion of each of the plurality of vent gas channels to a sensor housing. [9] The battery assembly of claim 8, wherein the vent gas collection member comprises a vent gas collection channel having a first channel portion extending across the heat exchange element, a second channel portion extending along the axis, and a third channel portion extending across the heat exchange element, the third channel portion comprising a sensor housing. [10] Vehicle comprising: a body, a plurality of wheels connected to the body; an electric drive unit mounted in the body and connected to at least one of the plurality of wheels; and a battery assembly as claimed above, which is operatively connected to the electric drive unit.

Images