Sealed battery case

Abstract

Battery enclosure systems, methods for venting gases from batteries, and vehicles are provided. A battery enclosure system includes a carrier, a cover, an annular inner seal sealing the carrier to the cover and defining an inner enclosed chamber and an annular outer enclosed channel, and a battery located within the inner enclosed chamber.

Description

[0001] The disclosure relates to motor vehicle battery systems, in particular to systems and methods for enclosing and venting battery packs.

[0002] Electrochemical battery packs are used in a variety of battery-electric systems. In particular, on board an electric vehicle (EV), a high-energy traction battery pack is connected to a DC bus, with the traction battery pack comprising a number of cylindrical, prismatic, or pouch-shaped electrochemical battery cells suitable for the application. The DC bus then supplies one or more electric drive motors and their associated power electronic components during battery discharge mode. The same DC bus delivers the charging current to the individual battery cells of the battery pack during the battery charging process.

[0003] Traction batteries for electric vehicles and other battery-electric systems typically use lithium- or nickel-based battery chemistry. In lithium-ion battery cells, for example, the movement of electrons and lithium ions generates electricity to power the aforementioned electric drive motor(s). Charging and discharging the battery cells generates heat. This heat must be dissipated from the battery cells, for example, via the circulation of the battery coolant, cooling plates, or cooling fins. In rare cases, damage, aging, or degradation of battery cells can cause the heat generated in a battery cell or battery pack to exceed the available cooling capacity. This condition is referred to, both here and in the professional literature, as thermal runaway.

[0004] Accordingly, there is a need for systems and methods for enclosing EV batteries that protect adjacent vehicle components from the heat emitted by the battery, while simultaneously reducing hardware costs and complexity, improving reliability, and providing enhanced functionality and redundancy. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the following detailed description and the accompanying claims when considered in conjunction with the accompanying drawings and the preceding technical field and background.

[0005] In one embodiment, a battery housing system comprises a support, a cover, an annular inner seal that seals the support to the cover and defines an inner enclosed chamber and an annular outer enclosed channel, and a battery located in the inner enclosed chamber.

[0006] In certain embodiments of the battery housing system, the annular inner seal is formed by a sealing disc.

[0007] In certain embodiments, the battery housing system further comprises an annular outer seal formed by adhesive, which connects a circumference of the support to a circumference of the cover, and the annular outer enclosed channel is located between the annular inner seal and the annular outer seal.

[0008] In certain embodiments of the battery housing system, the annular inner seal is designed to fail at a first pressure, and the annular outer seal is designed to withstand the first pressure.

[0009] In certain embodiments, the battery housing system further comprises an outlet device that is connected to the annular outer enclosed channel.

[0010] In certain embodiments, the battery housing system further comprises an outlet device formed in the cover, which is connected to the annular outer enclosed channel.

[0011] In certain embodiments, the battery housing system further comprises an outlet device formed in the carrier and connected to the annular outer enclosed channel.

[0012] In certain embodiments, the battery housing system further comprises a distributor connected to the annular inner seal, and the annular outer enclosed channel is located between the annular inner seal and the distributor.

[0013] In certain embodiments, the battery housing system also includes an outlet device formed in the distributor.

[0014] In another embodiment, a method for venting gases from a battery comprises arranging the battery between a support and a cover, sealing the cover to the support to form an annular inner seal enclosing an inner chamber, wherein the battery is arranged in the inner chamber and wherein the annular inner seal separates the inner chamber from an annular outer enclosed chamber, separating the cover from the support at a defect in the annular inner seal due to increased pressure within the inner chamber, allowing the gases to flow from the inner chamber to the annular outer enclosed chamber at the defect, and allowing the gases to flow from the annular outer enclosed chamber through a particle filter.

[0015] In certain embodiments of the method, the annular inner seal is formed by a sealing disc.

[0016] In certain embodiments, the method further comprises sealing a cover circumference of the cover to a support circumference of the support with an adhesive to form an annular outer seal, and the annular outer enclosed chamber is located between the annular inner seal and the annular outer seal.

[0017] In certain embodiments of the method, the annular inner seal is designed to fail under the increased pressure, and the annular outer seal is designed to withstand the increased pressure.

[0018] In certain embodiments, the method further comprises forming the particle filter in the carrier and / or the cover at a selected location or connecting the particle filter to the carrier and / or the cover at a selected location.

[0019] In certain embodiments, the method further includes directing the gas flow through the particle filter in a desired direction.

[0020] In another embodiment, a vehicle comprises a battery and a battery housing system, and the battery housing comprises a support with a support circumference, a cover with a cover circumference and an annular inner seal connecting the support circumference to the cover circumference and defining an inner enclosed chamber and an annular outer enclosed chamber, wherein the battery is arranged in the inner enclosed chamber.

[0021] In certain embodiments of the vehicle, the annular inner seal is formed by a sealing disc.

[0022] In certain embodiments of the vehicle, the battery housing system further comprises an annular outer seal formed by adhesive, which connects the support circumference to the cover circumference, and the annular outer enclosed chamber is located between the annular inner seal and the annular outer seal.

[0023] In certain embodiments of the vehicle, the battery housing system further includes a particulate filter that is connected to the annular outer enclosed chamber.

[0024] In certain embodiments of the vehicle, the battery housing system further comprises a distributor connected to the annular inner seal, and the annular outer enclosed chamber is located between the annular inner seal and the distributor. Brief description of the drawings

[0025] The present disclosure is described below in conjunction with the following drawings, where the same reference numerals denote the same elements: Fig. Figure 1 is a schematic, perspective view of an electric vehicle with a cutout showing a battery housed in a battery housing system with an interconnected support and a cover according to exemplary embodiments. Fig. Figure 2 is a schematic system diagram showing the battery housing system, as shown in Figure 2. Fig. Figure 1 shows exemplary embodiments. Fig. Figure 3 is a schematic partial view of the battery housing system of Fig. 2, which focuses on the inner and outer seal according to exemplary embodiments. Fig. Figure 4 is a schematic partial view of a battery housing system, similar to that in Fig. 3, and illustrates alternative structures in accordance with exemplary embodiments. Fig. 5 is a schematic partial view of a battery housing system, similar to that in the Fig. 3 - 4, and shows alternative structures in accordance with exemplary embodiments. Fig. Figure 6 is a schematic top view of a battery housing system according to Fig. 2 in accordance with exemplary embodiments. Fig. Figure 7 is a flowchart showing a method for venting gases from a battery in accordance with certain embodiments. Detailed description

[0026] The following detailed description is merely exemplary and is not intended to limit the application and use of the embodiments described herein. Furthermore, there is no intention to be bound by any express or implied theories set forth in the preceding introduction, summary, or the following detailed description.As used herein, the term “module” refers to any hardware, software, firmware, electronic control unit or component, processing logic and / or processor device, individually or in any combination, including, but not limited to: application-specific integrated circuit (ASIC), electronic circuit, processor (common, dedicated or group) and memory executing one or more software or firmware programs, combinational logic circuit and / or other suitable components providing the described functionality.

[0027] Embodiments of the present disclosure can be described herein in the form of functional and / or logical block components and various processing steps. Such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, or the like, which, under the control of one or more microprocessors or other devices, can perform a variety of functions.Furthermore, the person skilled in the art will recognize that embodiments of the present disclosure can be used in conjunction with any number of automated driving systems, including cruise control systems, automated driver assistance systems and autonomous driving systems, and that the vehicle system described here is merely an exemplary embodiment of the present disclosure.

[0028] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual components of the systems) are not described in detail herein. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and / or physical couplings between the various elements. It should be noted that in an embodiment of the present disclosure, many alternative or additional functional relationships or physical connections may exist.

[0029] For the purposes of this description, the use of the singular includes the plural and vice versa, unless expressly excluded. The terms "and" and "or" apply in both the subjunctive and disjunctive moods, and the words "including," "containing," "comprehensive," "exhibiting," and the like mean "including without limitation." Furthermore, words of approximation such as "about," "almost," "essentially," "generally," "approximately," etc., may be used here to mean "at, close to, or almost at" or "within 0-5% of" or "within acceptable manufacturing tolerances," or logical combinations thereof. A component that is "configured" to perform a particular function is capable of performing that function without modifications, and not merely has the potential to perform that function after further modifications.In other words, if the described hardware is explicitly configured to perform the specified function, it is specifically selected, created, implemented, used, programmed and / or designed to perform the specified function.

[0030] Referring to the drawings, where identical reference symbols correspond, wherever possible, to identical or similar components in the different figures, it is in Fig. Figure 1 shows an electric vehicle 10 comprising a battery module 10, a battery cell 30, or a plurality of battery cells in a battery stack 30. The term "battery" as used herein alone may refer to a battery module, a battery cell, or a cell stack. The electric vehicle 10 further comprises a battery housing system 100 for enclosing the battery 30. The term "battery pack" alone may refer to a battery and the battery housing system in which the battery is housed.

[0031] The electric vehicle 10 comprises a vehicle chassis 12. The battery housing system 100 comprises a battery carrier 14. The battery 30 is attached to the battery carrier 14, which in turn is attached to the vehicle chassis 12 in order to attach the battery 30 to the electric vehicle 10.

[0032] The electric vehicle 10 may also include a battery disconnect unit 16 which is connected to the battery 30 and establishes an electrical connection between the battery 30 and an electrical system (not shown) of the electric vehicle 10.

[0033] The battery housing system 100 further comprises a battery cover 18 that extends over and around the battery 30. The battery cover 18 protects the battery 30 from damage and provides electrical insulation for the high voltage of the battery 30.

[0034] Fig. Figure 2 is a schematic cross-sectional representation showing an exemplary embodiment of the battery housing system 100. Fig. 1 shows. Fig. Figure 2 illustrates that the battery carrier 14 of the battery housing system 100 comprises a base element 141 that extends laterally to side walls 142. As shown, the side walls 142 extend upwards to an annular flange element 143. The annular flange element 143 extends laterally from the side walls 142 to a peripheral outer edge 144 of the battery carrier 14. As shown, the annular flange element 143 defines a carrier circumference 145. The battery carrier 14 can be made of a metal such as steel or aluminum, or another suitable material.

[0035] As in Fig. As shown in Figure 2, the battery cover 18 comprises a base element 181 that extends laterally to the side walls 182. As shown, the side walls 182 extend downwards to an annular flange element 183. The annular flange element 183 extends laterally from the side walls 182 to a peripheral outer edge 184 of the battery cover 18. As shown, the annular flange element 183 defines a cover perimeter 185. The battery cover 18 can be made of a metal such as steel or aluminum, or another suitable material. In certain embodiments, the battery cover 18 can be made of a non-metal material and / or be formed from a composite material.

[0036] Fig. Figure 2 further shows that the carrier circumference 145 and the cover circumference 185 are sealed together near the outer edges 144 and 184 by an outer seal 300. The outer seal 300 can be, for example, an adhesive such as a room-temperature vulcanizing (RTV) adhesive. An exemplary adhesive for forming the outer seal 300 is a silicone, a polymer, or another material that can withstand the high-temperature environment of the battery 30. The outer seal 300 is annular and continuous.

[0037] Fig. Figure 2 also shows that the carrier circumference 145 and the cover circumference 185 are sealed together by an inner seal 200. The inner seal 200 can be, for example, a mechanical seal, such as a sealing washer. The inner seal 200 can, for example, be a press-fit compression seal. An example of an inner seal 200 is a static seal. An example of an inner seal 200 is annular and continuous. During assembly, the inner seal 200 can be formed by positioning matching sealing surfaces on the carrier 14 and the cover 18, aligning such sealing surfaces, and pressing the sealing surfaces together.

[0038] In one exemplary embodiment, the outer seal 300 is configured to withstand a higher pressure than the inner seal 200. Specifically, the inner seal 200 will fail at a selected elevated pressure if the battery cover 18 detaches from the battery carrier 14 at a defect location. At the same elevated pressure, the outer seal 300 remains intact and continuously connects the battery cover 18 to the battery carrier 14 around circumferences 145 and 185. In certain embodiments, the selected elevated pressure at which the inner seal 200 fails may be 20 kilopascals (kPa), although the selected elevated pressure may be any suitable pressure that could occur during a failure event, such as thermal runaway.

[0039] While the inner seal 200 is designed to fail under increased pressure, e.g. during a thermal leakage event, the inner seal 200 is designed to remain tight at typical operating pressures of the battery cell or battery 30, e.g. at pressures of less than 20 kilopascals (kPa).

[0040] The inner seal 200, the side walls 142 and 182, and the bottom elements 141 and 181 define and enclose an inner chamber 250. As shown, the battery 30 is located in the inner chamber 250.

[0041] The outer seal 300, the flange elements 143 and 183, and the inner seal 200 form an annular outer chamber or channel 350. The inner seal 200 separates the inner chamber 250 from the annular outer channel 350.

[0042] In the described setup, the battery housing system 100 is configured such that, in the event of a failure of the inner seal 200 at a fault location, gas with a relatively higher pressure inside the inner chamber 250 flows through the inner seal 200 at the fault location to the annular outer channel 350.

[0043] As in Fig. As shown in Figure 2, the battery housing system 100 is further provided with an outlet device 400, such as a vent channel, a particle filter, a spark arrestor, and / or another device for reducing sparks or fire. Each outlet device 400 is located outside the inner seal 200, relative to the inner chamber 250. The outlet device 400 can be formed in or coupled to the battery carrier 14 (as outlet device 414) and / or the battery cover 18 (as outlet device 418) and be configured to receive gas or fluid from the annular outer channel 350. The outlet device 400 can be made of stainless steel or another material suitable for withstanding high temperatures and pressures. In certain embodiments, the device 400 is formed in the battery carrier 14 and / or the battery cover 18.For example, a pattern of cavities or openings can be punched into the battery carrier 14 and / or the battery cover 18 to form a mesh or filter. The cavities can be configured with a critical dimension or diameter such that they capture solid particles exiting the annular outer channel 350 with the exhaust gas.

[0044] In certain embodiments, exhaust devices 400 are arranged continuously around the circumference 145 or 185 of the battery carrier 14 and / or the battery cover 18. In other embodiments, the exhaust devices 400 can be spaced apart circumferentially around the circumference 145 or 185 of the battery carrier 14 and / or the battery cover 18. For example, the exhaust devices 400 can be arranged at two, three, four, five, six, or any other suitable number of locations. In certain embodiments, the exhaust devices 400 can be arranged at equal intervals. Alternatively, the devices 400 can be arranged at selected locations to direct the exhaust gases from the battery housing system 100 in a preferred direction, i.e., away from other vehicle components that might be at risk from the heat of the exhaust gases exiting the device(s) 400.In such embodiments, the position of the outlet devices 400 may not be symmetrical with respect to the circumferences 145 and 185 of the battery carrier 14 and the battery cover 18. Furthermore, it should be noted that the outlet devices 400 are not required on all flange faces and can be arranged only where desired, i.e., the outlet devices 400 can be present only on the battery carrier 14 or only on the battery cover 18.

[0045] The structure of the flanges 143 and 183 can be designed such that the flow of exhaust gases through the device(s) 400 is directed in the desired directions. For example, the shape of the flanges can have bends or other geometries to align the outlet devices 140 in a desired orientation and to direct the flow of exhaust gases from them in a desired direction.

[0046] Fig. Figure 3 shows a focused view of the flanges 143 and 183 and the annular outer channel 350 of the battery housing system 100. Fig. 2. In the embodiments of Fig. 2 and Fig. 3 The flange 143 of the battery support 14 is essentially planar, i.e., annular or flat and annular. The flange 143 of the battery support may have a single annular wall 241 extending to the edge 144.

[0047] As shown, the flange 183 of the battery cover 18 has a bend, i.e., it is provided with a projection 340 extending away from the flange 143. Consequently, the annular outer channel 350 lies entirely above the plane of the flange 143. As shown, the flange element 183 of the battery cover can have a wall 281, which is annular or flat. The wall 281 extends laterally to a side wall 282, which can be cylindrical. The side wall 282 extends away from the flange element 143 of the support and connects to an end wall 283. The end wall 283 can be annular or flat and extends laterally to a side wall 284. The side wall 284 can be cylindrical. The side wall 284 extends toward the flange element 143 of the support and connects to an end wall 285. The end wall 285 ends at the outer edge 184 and can be ring-shaped or flat ring-shaped.As shown, the inner seal 200 is attached to and between wall 281 and wall 241. Furthermore, the outer seal 300 is attached to and between wall 285 and wall 241. The annular outer channel 350 is bounded by the inner seal 200, wall 241, outer seal 300, wall 285, side wall 282, end wall 283, side wall 282, and wall 281. By selectively forming a device 400 on one of the side walls 282 or 284 and / or on the end wall 283 or wall 241, the flow direction of the exhaust gases from the device 400 can be controlled. As shown in... Fig. As can be seen in Figure 3, the angle of each of the walls 282, 283 and 284 can be designed such that an outlet device 400 formed thereon is aligned so that gases escape in a desired direction.

[0048] Fig. Figure 4 shows a further embodiment of the structure of the flanges 143 and 183 and the annular outer channel 350 of the battery housing system 100. Fig. 4 The flanges 143 and 183 each have a bend, so that the projection 340 is formed by a non-planar flange 143 of the battery carrier and a non-planar flange 183 of the battery cover.

[0049] As shown, the flange 143 of the battery carrier includes a wall 241, which is annular or flat. The wall 241 extends laterally to a side wall 242, which may be cylindrical.

[0050] The side wall 242 extends away from the cover flange 183 and adjoins an end wall 245. The end wall 245 can be ring-shaped or flat ring-shaped and extends laterally to the outer edge 144.

[0051] The flange 183 of the battery cover also includes an annular or flat wall 281. The wall 281 extends laterally to a side wall 282, which may be cylindrical. The side wall 282 extends towards the support flange 143 and connects to an end wall 285. The end wall 285 may be annular or flat annular and extends laterally to the outer edge 184.

[0052] As shown, the inner seal 200 is attached to and between wall 281 and wall 241. Furthermore, the outer seal 300 is attached to and between wall 285 and wall 245. The annular outer channel 350 is bounded by the inner seal 200, wall 241, side wall 242, wall 245, outer seal 300, wall 285, side wall 284, and wall 281. By selectively forming a device 400 on one of the side walls 242 or 284 and / or on wall 281 or wall 245, the flow direction of the exhaust gases from the device 400 can be controlled. It should be noted again that the walls 241, 242, 245, 281 and 284 can be shaped at any angle in order to provide the outlet devices 400 formed on them with a desired outlet flow direction.

[0053] The Fig. Figures 2 to 4 show two structural designs for enclosing the annular outer channel 350 with the flange 143 of the battery carrier and the flange 183 of the battery cover, but other arrangements are also conceivable.

[0054] Fig. Figure 5 shows another embodiment of a battery housing system 100 with an inner seal 200 that connects the flange 143 of the battery carrier and the flange 183 of the battery cover. Fig. 5 The flange of the battery support 143 is sealed to the flange of the battery cover 183 by the inner seal 200. As shown, a housing structure 500, such as an annular manifold, can be connected to the sealed flanges 143 and 183 via fasteners 600. For example, a mechanical fastener 600, such as a bolt and nut, can secure the housing structure 500 to the sealed flanges 143 and 183. The fasteners 600 can be arranged circumferentially around the battery support 143 and the battery cover 18. The housing structure 500 can include outlet devices 400, such as spark arresters or vent channels.

[0055] As shown, the housing structure 500 can extend from an end 504 located below the flange 143 of the battery support to an end 508 located above the battery cover flange 183. The housing structure 500 can comprise a lower element 501 extending laterally outward from the end 504 to an end element 502. As shown, the end element 502 can extend upward from the lower element 501 to an upper element 503. Furthermore, the upper element 503 can extend laterally from the end element 502 to the end 508. The lower element 501 and the upper element 503 can each be annular or ring-shaped. The end element 502 can be cylindrical or flat.

[0056] As shown, the lower element 501 can be sealed to the flange 143 of the battery support near the outer edge 144, and the upper element 503 can be sealed to the flange 183 of the battery cover near the outer edge 184, by external seals 300. In certain embodiments, each external seal 300 is a cure-in-place seal or another suitable sealing mechanism. In certain embodiments, each external seal 300 is formed by an adhesive.

[0057] As shown, the outlet devices 400 can be attached to the lower part 501, the end element 502, and / or the upper part 503. By selectively forming the devices 400 at the desired locations, the flow direction of the exhaust gases from the device 400 can be controlled. The lower element 501, the end element 502, and the upper element 503 can be shaped at any desired angle to provide the outlet devices 400 formed thereon with a desired outlet flow direction.

[0058] Fig. Figure 6 is a schematic top view showing the flow path of the vented gases from a superheating point to an outlet of the battery housing system 100. As shown, the cover 18 and the support 14 (concealed by the cover 18) are sealed to each other at the inner seal 200 and the outer seal 300. The inner seal 200 encloses an inner chamber 250 in which the battery 30 is located. The inner seal 200 and the outer seal 300 define an annular outer channel 350. A device 400 for venting gases is formed in conjunction with the annular outer channel 350.

[0059] If an overheating event, such as thermal runaway, occurs at a point 90 in the battery 30, a local temperature and pressure increase results. This temperature and pressure increase causes the inner seal 200 to fail at a fault location 291. As a result, heated gases flow from the inner chamber 250 into the annular outer channel 350 in the direction of arrow 91. As shown, the heated gases can flow in the direction of arrows 92 and 93 to the nearest outlet device 400. The heated gases can then exit the battery housing system 100 through the outlet device 400, as indicated by arrow 94.

[0060] As shown, after exiting the inner chamber 250, the heated gases are separated from the other battery components by the remaining inner seal 200, which has not opened. This protects other battery components from the heat of the heated gases and minimizes damage to the battery 30. Furthermore, by selecting the location and orientation of the exhaust devices 400, the escaping gases can be directed in the direction of arrow 94 and away from vulnerable vehicle components 99.

[0061] Fig. Figure 7 illustrates a procedure 1000 for venting gases from a battery.

[0062] Method 1000 includes in step 1005 the arrangement of the battery between a battery holder and a battery cover.

[0063] Procedure 1000 comprises, in step 1015, sealing the battery cover to the battery holder to form an annular inner seal that encloses an inner chamber. After the battery cover is sealed to the battery holder, the battery is located in the inner chamber.

[0064] Method 1000 may further comprise in process 1025 sealing a circumference of the battery cover with a circumference of the battery carrier to form an annular outer seal.

[0065] Method 1000 may also include, in operation 1035, forming a device, such as a particulate filter, in the battery carrier and / or in the battery cover at a selected location, or connecting a device, such as a particulate filter, to the battery carrier and / or the battery cover at a selected location. It should be noted that the sequence of operations in Fig.7 is not limited by the illustration. For example, the device can be inserted into or connected to the battery holder and / or battery cover before operation 1005, before operation 1015 and / or before operation 1025.

[0066] Procedure 1000 may include, in process 1045, operating a vehicle with electricity from the battery.

[0067] Procedure 1000 comprises, in step 1055, separating the battery cover from the battery carrier at a defect point in the annular inner seal due to increased pressure in the inner chamber. For example, thermal runaway can lead to an increase in temperature and pressure, causing the annular inner seal to fail at a defect point.

[0068] In process 1065, procedure 1000 includes the flow of venting gases from the inner chamber into the annular outer enclosed chamber at the fault location.

[0069] Method 1000 comprises, in step 1075, the discharge of exhaust gases from the annular outer enclosed chamber through an outlet device, e.g., a particulate filter. The outlet device can capture particles in the exhaust gases to prevent contact of the particles with oxygen and a resulting ignition.

[0070] Procedure 1000 can include, in process 1085, directing the flow of exhaust gases through the particulate filter in a desired direction, e.g. away from vulnerable vehicle components.

[0071] As described herein, a battery enclosure system protects the internal battery components during an overheating situation by introducing a planned failure of an internal seal at a fault location. In certain embodiments, the fault location is near the overheating point. Furthermore, the planned failure causes heated gas from the interior containing the battery to flow into an annular outer channel. The battery remains protected from the heated gases in the annular channel by the remaining, undamaged internal seal. Additionally, a vent or vents are arranged in conjunction with the annular outer channel to direct the heated gases from the battery enclosure in a desired direction, such as away from other vehicle components.

[0072] Furthermore, due to the structural design of the battery housing system, the outer seal can be cut open during maintenance without damaging the battery pack. Specifically, the outer seal is spaced away from the battery pack and the high-voltage components within it, and the inner seal is located between the outer seal and the battery pack. This simplifies maintenance compared to existing systems.

[0073] Certain embodiments herein incorporate a full-pack seal provided by an inner gasket to improve the venting performance of the battery pack or module while mitigating the shortcomings of existing full-pack seals. In particular, the placement of full-pack adhesive gaskets can lead to damage to the inner packing components during maintenance, i.e., when the adhesive gasket is cut to access the internal components. In this context, a full-pack compression seal can be employed to improve serviceability. During rapid thermal runaway (TRP), the flanges of the battery tray or battery cover can deform due to the increased internal pressure and high temperatures within the pack, leading to failure of the inner gasket.This failure is counteracted here by the use of an outer seal between the battery holder and the battery cover, which forms a channel with the inner seal. Thus, if the heat and pressure inside the battery pack increase, the compression in the inner seal is lost, causing it to fail and creating a leak path for hazardous hot gases to escape from the pack. These hot gases are then channeled along the outer seal to a device. This venting device can include a particle filter, a spark arrestor, or a venting system. The venting device's function is to evacuate the hot gases from the outer channel. Therefore, if the inner seal fails during a TRP event, no heated particles can escape from the battery casing. Consequently, spontaneous combustion is prevented.

[0074] Certain embodiments herein permit the failure of an internal seal to allow venting during the TRP.

[0075] Certain embodiments herein utilize the sealing area of ​​the battery support and battery cover of a battery housing as an exhaust system. In certain embodiments, the sealing area of ​​the battery support and battery cover is used as an exhaust vent to utilize the surface area of ​​the largest components of the pack (thermal mass made of metal) for exhaust gas cooling. Thus, the area between the inner and outer seals is used as an exhaust vent, passively cooling the gases before they are released to the environment. Certain embodiments herein improve the heat transfer of hot TRP gases before the gases are released from the battery housing system. Certain embodiments herein improve the utilization of the structure's heat sink, thereby mitigating heat transfer to sensitive battery cells within the battery pack.

[0076] A larger cross-sectional area for venting is achieved by using the sealing area instead of small vent points on the manifold. In certain embodiments, the sealing area is used as a spark arrestor for a particle management system. In certain embodiments, the spark arrestor is punched directly into the battery cover and / or battery tray within the sealing area. In certain embodiments, a spark arrestor or vent channel is attached as a separate part to the sealing flange assembly.

[0077] In certain embodiments, the annular sealing area (completely surrounding the battery pack) is used to transport the exhaust gas to specific and selected venting points on the vehicle. For example, the heated gas can be directed in a channel formed within the sealing area to specific locations where the vehicle is least susceptible to high-temperature gases, i.e., far away from sensitive components. At each specific location, a device is provided for venting the heated gas from the battery housing in a preferred direction.

[0078] Certain embodiments provide that heated gases can escape from the battery pack in more than one direction.

[0079] In certain embodiments, the cross-sectional area of ​​the vent from the outlet device, i.e. the spark arrester, is adjusted based on the vehicle components so that the venting from the sealed passage takes place at the desired locations away from sensitive components.

[0080] In certain embodiments, the cross-sectional area of ​​the outlet device, i.e., the spark guard, is significantly enlarged compared to conventional vent openings in order to reduce the susceptibility to blockages.

[0081] In certain embodiments, the flow path of the heated gases from the channel to the outlet device is provided with bending elements to enable a constructed passage within the mounted area.

[0082] In certain embodiments, heat transfer to adjacent cells / modules is reduced if gases escape from the package to the nearest sealing defect.

[0083] Certain embodiments allow the use of battery covers made of composite materials. In such embodiments, the spark arrestor can be integrated into the battery tray, and the escaping gas can be directed away from the vehicle components and back onto the outer surface of the battery housing.

[0084] In certain embodiments, increased packing pressure is permitted during TRP, as the seal is not required under TRP conditions, while maintaining the serviceability of the battery pack.

[0085] In certain embodiments, the inner full-pack seal is a cost-effective seal (made from inexpensive “low thermal materials” that are insufficient to withstand high thermal conditions) to merely meet the pressure and temperature requirements during normal operation and to allow failure below TRP.

[0086] In certain embodiments, an external seal connecting the carrier and the cover seals against gases during a TRP event and presents high thermal challenges, but does not need to meet the standards for water ingress during normal operation. The external seal can, for example, be made of a high-temperature-resistant adhesive. Certain embodiments improve the serviceability of the battery pack by keeping the adhesive, which must be cut to open the battery casing, away from the sensitive internal components of the battery pack.

[0087] In certain embodiments, the outer seal, which meets the high thermal requirements, is located away from the high-voltage components in the battery, so that the outer seal can be serviced, i.e., it can be cut open without damaging the battery components.

[0088] In certain embodiments, the battery housing system can be optimized for venting during TRP without the need to unnecessarily add numerous venting devices to compensate for membrane clogging.

[0089] Certain embodiments herein reduce the susceptibility of the spark guard to blockages. Certain embodiments improve flowability by preventing a breathing membrane from being impaired due to membrane blockages in the flow openings.

[0090] Although at least one exemplary embodiment has been presented in the preceding detailed description, it should be recognized that a multitude of variants exist. It should also be recognized that the exemplary embodiment or embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the preceding detailed description is intended to provide the person skilled in the art with a practical guide for implementing the exemplary embodiment or embodiments. It is understood that various modifications to the function and arrangement of the elements can be made without departing from the scope of the disclosure as set forth in the appended claims and their statutory equivalents.

Claims

[1] Battery housing system comprising: a carrier; a cover; an annular inner seal that seals the carrier to the cover and defines an inner enclosed chamber and an annular outer enclosed channel; and a battery that is located in the inner closed chamber. [2] Battery housing system according to claim 1, wherein the annular inner seal is formed by a sealing disc. [3] Battery housing system according to claim 2, further comprising an annular outer seal formed by adhesive and connecting a circumference of the carrier to a circumference of the cover, wherein the annular outer enclosed channel is arranged between the annular inner seal and the annular outer seal. [4] Battery housing system according to claim 3, wherein the annular inner seal is designed to fail at a first pressure, and wherein the annular outer seal is designed to withstand the first pressure. [5] Battery housing system according to claim 1, further comprising an outlet device that is connected to the annular outer enclosed channel, wherein the outlet device is formed in the cover or in the support, and wherein the outlet device is connected to the annular outer enclosed channel. [6] Battery housing system according to claim 1, further comprising: a distributor connected to the annular inner seal, wherein the annular outer enclosed channel is arranged between the annular inner seal and the distributor; and an outlet device formed in the distributor. [7] Method for venting gases from a battery, the method comprising: Arranging the battery between a support and a cover; Sealing the cover to the carrier to form an annular inner seal enclosing an inner chamber, wherein the battery is arranged in the inner chamber and wherein the annular inner seal separates the inner chamber from an annular outer enclosed chamber; Separation of the cover from the carrier at a defect point in the annular inner seal due to increased pressure within the inner chamber; Flow of gases from the inner chamber into the ring-shaped outer enclosed chamber at the fault location; and Gases are extracted from the ring-shaped outer enclosed chamber through a particle filter. [8] Method according to claim 7, further comprising sealing a cover circumference of the cover on a carrier circumference of the carrier with an adhesive to form an annular outer seal, wherein the annular outer enclosed chamber is arranged between the annular inner seal and the annular outer seal. [9] Method according to claim 7, wherein the annular inner seal is designed to fail under the increased pressure, and wherein the annular outer seal is designed to withstand the increased pressure. [10] Method according to claim 7, further comprising directing a flow of the gases through the particle filter in a desired direction.

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