Multi-element cooling system

Abstract

A cooling system for a multi-cell rechargeable energy storage system (RESS) having a plurality of battery cells arranged in individual battery modules includes a main coolant circuit configured to circulate a coolant. The cooling system additionally includes a plurality of coolant branches arranged in parallel. Each coolant branch is configured to receive a portion of the coolant from the main coolant circuit to remove thermal energy from one of the respective battery modules. The cooling system further includes at least one flow valve configured to regulate the coolant circulating through the main coolant circuit and distribute it to the plurality of coolant branches. One-way valves may be used to control the flow of coolant from the respective coolant branches. A motor vehicle employing such a RESS and the cooling system is also included.

Description

introduction

[0001] The present disclosure relates to a multi-branch cooling system for a multi-cell rechargeable energy storage system (RESS).

[0002] A battery system for generating and storing electrical energy typically includes one or more battery cells to power a load. Multiple battery cells can be arranged in close proximity to each other to form a battery module, and multiple battery modules can be combined to form a battery pack array. Batteries can be broadly divided into primary and secondary batteries. Primary batteries, also known as disposable batteries, are designed to be used until depleted and then simply replaced with new ones. Secondary batteries, commonly referred to as rechargeable batteries, utilize a special chemistry that allows them to be repeatedly recharged and reused, offering economic, environmental, and user-friendliness advantages compared to disposable batteries.

[0003] Rechargeable batteries can be used to power a wide variety of items, from toys and consumer electronics to motor vehicles. Certain chemical properties of rechargeable batteries, such as lithium-ion cells, as well as external factors, can lead to internal reaction rates that generate significant amounts of thermal energy. If a battery cell is exposed to high temperatures for an extended period, thermal runaway can occur, where heat from a single cell spreads to neighboring cells in the module, affecting the entire battery assembly. Accordingly, the thermal energy must be effectively dissipated to reduce heat buildup and the resulting performance degradation of the battery system. Generally, devices such as heat sinks or cooling plates with circulating coolant are used to dissipate heat from battery systems. Description

[0004] A multi-cell rechargeable energy storage system (RESS) comprises a multitude of battery cells arranged in individual battery modules. The RESS also includes a cooling system with a main coolant circuit designed to circulate a coolant. The RESS further includes multiple coolant branches arranged in parallel. Each coolant branch is configured to receive a portion of the coolant from the main circuit to dissipate heat energy from its respective battery module. Additional parallel cooling branches may be used to circulate coolant through other internal battery components requiring liquid cooling, such as a battery disconnect unit (BDU), electrical connectors, and a DC / DC converter to supply the vehicle with 12 V / 48 V power.The RESS further includes at least one flow valve configured to regulate the coolant circulating through the main coolant circuit and to distribute it to the multitude of coolant branches.

[0005] The flow control valve can be a multi-way valve assembly located at a connection between the main coolant circuit and the multiple coolant branches. Such a multi-way valve can be configured to control the flow of coolant into each of the coolant branches.

[0006] Alternatively, a number of throttle valves can regulate the flow of coolant from the main coolant circuit. Each throttle valve can be located in one of the coolant branches upstream of the corresponding battery module and configured to control the flow of coolant into that specific coolant branch.

[0007] Each coolant branch may contain a one-way valve configured to control the flow of coolant from that particular coolant branch.

[0008] The cooling system may also include a fluid pump configured to circulate the coolant through the main coolant circuit.

[0009] The cooling system may additionally include a coolant cooler configured to extract thermal energy from the coolant in the main coolant circuit.

[0010] The cooling system may also include a coolant heater configured to supply thermal energy to the coolant in the main coolant circuit.

[0011] The multi-cell RESS can also include an electronic control unit configured to regulate the operation of the flow valve(s), fluid pump, coolant cooler, and coolant heater.

[0012] The electronic control unit can be configured to regulate the temperature of individual battery modules via the fluid pump, coolant radiator, and / or coolant heater. The electronic control unit can also regulate the temperature of other components or subsystems, such as the battery distribution unit (BDU), electrical connections, and DC / DC converter.

[0013] The electronic control can additionally be configured to regulate the temperature of the individual battery modules by distributing the flow of coolant via the flow valve(s) to the multitude of coolant branches.

[0014] A motor vehicle using a rechargeable multi-cell rechargeable energy storage system (RESS) with the cooling system described above is also disclosed.

[0015] The above features and advantages, as well as other features and advantages of the present disclosure, will be readily apparent from the following detailed description of the embodiment(s) and the best embodiment(s) of the disclosed disclosure in conjunction with the accompanying drawings and claims. Brief description of the drawings Fig. Figure 1 is a schematic top view of an embodiment of a motor vehicle comprising multiple energy sources and a multi-cell rechargeable energy storage system (RESS) configured to generate and store electrical energy used by vehicle systems including the energy sources according to the disclosure. Fig. 2 is a schematic representation of the in Fig. 1 RESS shown, including an embodiment of a coolant system with a main coolant circuit and several parallel coolant branches as a subsystem for dissipating heat energy from individual battery modules according to the disclosure. Fig. 3 is a schematic representation of the in Fig. 1 RESS shown, including a further embodiment of a coolant system with a main coolant circuit and several parallel coolant branches as a subsystem for dissipating heat energy from individual battery modules according to the disclosure. Detailed description

[0016] The embodiments of the present disclosure described herein are to be understood as examples. Other embodiments may take different and alternative forms. Furthermore, the drawings are generally schematic and not necessarily to scale. Some features may be enlarged or reduced to show details of certain components. Therefore, specific structural and functional details disclosed herein are not to be understood as limiting, but merely as a representative basis to show the person skilled in the art how to apply the present description in various ways.

[0017] Certain terms are used in the following description for reference purposes only and should therefore not be interpreted as limitations. For example, terms such as "top" and "bottom" refer to directions in the referenced drawings. Terms such as "front," "rear," "in front," "back," "left," "right," "behind," "side," "upward," "downward," "upper," and "lower," etc., describe the orientation and / or position of parts of the components or elements within a uniform but arbitrary frame of reference, which becomes clear by referring to the text and the associated drawings in which the components or elements in question are described.

[0018] Furthermore, terms such as "first," "second," "third," etc., may be used to describe individual components. This terminology may include the words expressly mentioned above, their derivatives, and words with similar meanings, and is used descriptively for the figures. It does not constitute a limitation of the scope of disclosure as defined by the attached claims. Moreover, the teachings may be described here in the form of functional and / or logical block components and / or various processing steps. It should be clear that such block components may comprise a set of hardware, software, and / or firmware components configured to perform the specified functions.

[0019] Referring to the drawings, in which similar reference numerals denote similar components, shows Fig. Figure 1 shows a schematic view of a motor vehicle 10 with a powertrain 12. The vehicle 10 can be, but is not limited to, a commercial vehicle, an industrial vehicle, a passenger vehicle, an aircraft, a watercraft, a train, or the like. It is also conceivable that the vehicle 10 is a mobile platform, such as an aircraft, an all-terrain vehicle (ATV), a boat, a personal mobility device, a robot, or the like, to serve the purposes of this disclosure. The powertrain 12 comprises a power source 14 configured to deliver a power source torque T (in Fig. (1 shown) for the propulsion of the vehicle 10 via driven wheels 16 relative to a road surface 18. The power source 14 is shown as an electric motor-generator.

[0020] As in Fig. As shown in Figure 1, the powertrain 12 can include an additional power source 20, such as an internal combustion engine. The power sources 14 and 20 can work together to power the vehicle 10. The vehicle 10 also includes a central processing unit (CPU) 22 and a multi-cell rechargeable energy storage system (RESS) 24, which is configured to generate and store electrical energy through heat-generating electrochemical reactions to supply the electrical energy to the power sources 14 and 20. The CPU 22 controls various systems of the vehicle 10, including the powertrain 12, to generate a predetermined torque T from the power source. The RESS 24 can be connected to the power sources 14 and 20, the CPU 22, and other vehicle systems via a high-voltage bus 25.

[0021] As in the Fig. As shown in Figures 1-3, the RESS 24 comprises a plurality of battery cells 28 arranged in individual battery groups or modules, such as a first module 30-1, a second module 30-2, and a third module 30-3. The modules 30-1, 30-2, 30-3 in question can be arranged electrically in series or in parallel. Although three individual battery modules are specifically shown, it is intended that the RESS 24 comprises at least two such modules, and several modules can be organized into battery packs or subpacks. The remainder of this disclosure focuses on the construction of the RESS 24 with three battery modules 30-1, 30-2, 30-3, each battery module having a desired number of battery cells 28. As shown in the Fig. 2 and Fig. As shown in Figure 3, each battery module 30-1, 30-2, 30-3 can include a corresponding battery module housing 32-1, 32-2, 32-3, configured to accommodate and support the corresponding battery cells 28. The RESS 24 can also include a battery housing 33 surrounded by an environment 34. The housing 33 of the battery set is configured to accommodate and support the battery modules 30-1, 30-2, 30-3.

[0022] As in the Fig. 2 and Fig. As shown in Figure 3, the RESS 24 also includes a cooling system 36 configured to dissipate thermal energy from various temperature-sensitive components of the RESS. The cooling system 36 includes a main coolant circuit 38 configured to circulate a coolant 40 through the RESS 24. As shown, the cooling system 36 also includes a fluid pump 42 configured to circulate the coolant 40 through the main coolant circuit 38. The cooling system 36 also includes a plurality of coolant branches, shown as a first branch 44-1, a second branch 44-2, and a third branch 44-3, which are in fluid communication with the main coolant circuit 38. Each of the coolant branches 44-1, 44-2, 44-3 extends through a corresponding battery module 30-1, 30-2, 30-3 near and along the associated battery cells 28.

[0023] Furthermore, each coolant branch 44-1, 44-2, 44-3 is configured to receive a portion of the coolant 40 from the main coolant circuit 38. The coolant branches 44-1, 44-2, 44-3 are arranged in parallel fluid flow to receive corresponding portions of the coolant 40. The coolant branches 44-1, 44-2, 44-3 are configured to independently circulate their respective portions of the coolant 40 and remove thermal energy from the corresponding battery modules 30-1, 30-2, 30-3. As shown, the main coolant circuit 38 can be in fluid connection with additional parallel coolant branches, for example to circulate the coolant through auxiliary power modules (APMs), a battery disconnect unit (BDU) with various electrical switches and relays, electrical connectors, a DC / DC converter to supply the vehicle with 12 V / 48 V, etc., each of which has a specific temperature requirement.

[0024] With continued reference to the Fig. 2 and Fig. 3. The RESS 24 can also include an inlet manifold 46 configured to connect the main coolant circuit 38 to the coolant branches 44-1, 44-2, and 44-3, and an outlet manifold 48 configured to reconnect the coolant branches to the main coolant circuit. Accordingly, the inlet manifold 46 and outlet manifold 48 together are designed to maintain the circulation of the coolant 40 through the cooling system 36. The cooling system 36 additionally includes at least one flow valve 50. The flow valve(s) 50 is / are configured to regulate the coolant 40 circulating through and being received by the main coolant circuit 38 and to distribute it to the individual coolant branches 44-1, 44-2, and 44-3.In other words, the flow valve(s) 50 is / are specifically designed and operated to independently regulate the coolant flow in each individual coolant branch 44-1, 44-2, 44-3.

[0025] As in Fig. As shown in Figure 2, the flow valve 50 can be a multi-way valve arrangement located in a connection, such as the inlet manifold 46, between the main coolant circuit 38 and the plurality of coolant branches 44-1, 44-2, 44-3 upstream of each battery module 30-1, 30-2, 30-3. The embodiment of the flow valve 50 as a multi-way valve arrangement can be configured to control the flow of the coolant 40 into each of the coolant branches 44-1, 44-2, 44-3. As shown in Figure 2, the flow valve 50 can be a multi-way valve arrangement located in a connection, such as the inlet manifold 46, between the main coolant circuit 38 and the plurality of coolant branches 44-1, 44-2, 44-3 upstream of each battery module 30-1, 30-2, 30-3. Fig. As shown in Figure 3, the flow valve(s) 50 can be a plurality of individual throttle valves 50-1, 50-2, 50-3. Each individual throttle valve 50-1, 50-2, 50-3 can be arranged in one of the plurality of coolant branches 44-1, 44-2, 44-3 upstream of the corresponding battery module 30-1, 30-2, 30-3 and configured to control the flow of the coolant 40 into the coolant branch in question.

[0026] As in the Fig. 2 and Fig. As shown in Figure 3, each coolant branch 44-1, 44-2, 44-3 can contain a corresponding one-way valve 52-1, 52-2, 52-3. The one-way valves 52-1, 52-2, 52-3 are configured to prevent backflow of the coolant 40 into the corresponding coolant branches 44-1, 44-2, 44-3. Each of the one-way valves 52-1, 52-2, 52-3 is located downstream of the flow valve(s) 50 and downstream of the corresponding battery module 30-1, 30-2, 30-3. Accordingly, each one-way valve 52-1, 52-2, 52-3 is configured to control the flow of the corresponding portion of the coolant 40 through and out of the respective coolant branch 44-1, 44-2, 44-3. The cooling system 36 can also include a variety of heat exchangers arranged in the main coolant circuit 38 to change the temperature of the coolant 40.One embodiment of such a heat exchanger can be, for example, a coolant cooler 54-1, which uses a refrigerant to extract thermal energy from the coolant 40 in the main coolant circuit 38. Another embodiment of such a heat exchanger can be a coolant heater 54-2, which, for example, uses an electrical resistor to supply thermal energy to the coolant 40.

[0027] As in the Fig. 2 and Fig.As shown in Figure 3, the multi-cell RESS 24 can additionally include an electronic control unit 56, which can either be electronically connected to the CPU 22 or be part of it. The electronic control unit 56 can be configured or programmed to regulate the operation of the cooling system 36, or it can be designed to control the operation of the RESS 24 as a whole. As shown, the electronic control unit 56 is in established communication with the fluid pump 42, the flow valve(s) 50, the coolant cooler 54-1, and the coolant heater 54-2. To support the necessary management of the RESS 24 and / or the cooling system 36, the electronic control unit 56 includes, in particular, a processor and tangible, non-volatile memory in which the necessary instructions are programmed.The controller's memory can be a suitable writable medium involved in providing computer-readable data or process instructions. Such a writable medium can take many forms, including, but not limited to, non-volatile and volatile media.

[0028] Non-volatile media for the electronic control 56 can include, for example, optical or magnetic disks and other permanent storage media. Volatile media can include, for example, dynamic random-access memory (DRAM), which can represent main memory. The instructions programmed into the control 56 can be transmitted via one or more transmission media, including coaxial cable, copper wire, and fiber optic cable, including lines that have a system bus coupled to a computer processor, or via a wireless connection. The memory of the electronic control 56 can also include a flexible disk, a hard disk, magnetic tape, another magnetic medium, a CD-ROM, a DVD, another optical medium, etc. The electronic control 56 can be configured or equipped with other necessary computer hardware, such as...with a high-speed clock generator, required analog-to-digital (A / D) and / or digital-to-analog (D / A) circuits, input / output (I / O) circuits and devices, and suitable signal conditioning and / or buffer circuits.

[0029] The algorithm(s) required by or accessible through the electronic control unit 56 can be stored in the control unit's memory and executed automatically to enable the operation of the RESS 24 and / or the cooling system 36. In particular, the algorithm(s) 58 can include a maintenance mode configured to monitor the operation of the fluid pump 42, the flow valve(s) 50, the coolant radiator 54-1, and the coolant heater 54-2. The electronic control unit 56 can be configured to control the temperature of the individual battery modules 30-1, 30-2, 30-3 via at least one of the components fluid pump 42, coolant radiator 54-1, and coolant heater 54-2. The electronic control unit 56 can further be configured, for example, to…via the algorithm(s) 58, that it regulates the temperature of the individual battery modules 30-1, 30-2, 30-3 by dividing the flow of the coolant 40 between the individual coolant branches 44-1, 44-2, 44-3 via the flow valve(s) 50.

[0030] The RESS 24 can, for example, also include individual temperature sensors 60-1, 60-2, 60-3, which are embedded in the corresponding battery modules 30-1, 30-2, 30-3 (as well as in the respective temperature sensors in the auxiliary power modules and the components of the subsystem, such as the BDU, the electrical connectors, and the aforementioned DC / DC converter) and are connected to the electronic control unit 56. The electronic control unit 56 can be programmed to receive temperature signals from the respective sensors 60-1, 60-2, 60-3 and compare the detected temperatures with a predetermined permissible temperature range 62 for the required operation of the corresponding battery modules 30-1, 30-2, 30-3 (and, using signals from additional dedicated sensors, compare the temperatures of auxiliary power modules and subsystem components). Such an permissible temperature range 62 can be empirically determined for a variety of operating modes, e.g.B. Cold start, continuous operation or heavy load operation of the RESS 24 and the vehicle 10.

[0031] The sensors 60-1, 60-2, 60-3 can also be used to control the cooling system 36 in a closed-loop system to stabilize the temperature of the battery modules 30-1, 30-2, 30-3 (as well as the auxiliary power modules and the components of the subsystem). If the temperature detected by one or more sensors 60-1, 60-2, 60-3 (or auxiliary power modules and subsystem components) is outside the permissible temperature range 62, the electronic control 56 can instruct the fluid pump 42 to increase or decrease the flow rate of the coolant 40 and to lower or raise the temperature of the coolant via the coolant cooler 54-1 or the coolant heater 54-2. Furthermore, the electronic control 56 can divide the flow of the coolant 40 between the individual coolant branches 44-1, 44-2, 44-3 by regulating the flow valve(s) 50.As a result, the coolant flow with increased or decreased temperature can be directed with a larger or smaller volume flow to one or more specific coolant branches 44-1, 44-2, 44-3 of the corresponding battery modules that are outside the permissible temperature range 62.

[0032] Overall, the structure of the parallel coolant branches of the cooling system 36 enables controlled distribution of the coolant to the individual battery modules. The flow valve(s) 50 upstream of the individual battery modules allows the subject to control the coolant flow. Corresponding one-way valves 52-1, 52-2, 52-3, arranged in parallel coolant branches, also contribute to the effectiveness of the cooling system by controlling the coolant flow through the respective coolant branches. Control over the coolant distribution, in turn, allows individual battery modules to have separate temperature settings, rather than, for example, unusual conditions within a single battery module forcing a coolant flow and / or temperature setting across the entire RESS.

[0033] The detailed description and the drawings or figures support and describe the disclosure, but the scope of the disclosure is defined exclusively by the claims. While some of the best modes and other embodiments for carrying out the claimed description have been described in detail, various alternative designs and embodiments exist for carrying out the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings or the features of different embodiments mentioned in this description are not necessarily to be understood as independent embodiments.Rather, it is possible that each of the features described in one of the exemplary embodiments can be combined with one or a multitude of other desired features of other embodiments, leading to other embodiments that are not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the scope and application of the appended claims.

Claims

[1] Multi-cell rechargeable energy storage system, RESS, comprising: a large number of battery cells arranged in individual battery modules; and a cooling system, including: a main coolant circuit configured to circulate a coolant; a plurality of parallel coolant branches, each coolant branch configured to receive a portion of the coolant from the main coolant circuit to remove thermal energy from one of the corresponding battery modules; and at least one flow valve configured to regulate the coolant circulating through the main coolant circuit and to distribute it to the multitude of coolant branches. [2] Multi-cell rechargeable energy storage system according to claim 1, wherein the at least one flow valve is a multi-way valve arrangement arranged in a connection between the main coolant circuit and the plurality of coolant branches and configured to control a flow of coolant into each of the coolant branches. [3] Multi-cell rechargeable energy storage system according to claim 1, wherein the at least one flow valve is a plurality of throttle valves, each throttle valve being arranged in one of the plurality of coolant branches upstream of the corresponding battery module and configured to control a flow of coolant into the coolant branch concerned. [4] Multi-cell rechargeable energy storage system according to claim 1, wherein each coolant branch includes a one-way valve configured to control the flow of coolant from the coolant branch concerned. [5] Multi-cell rechargeable energy storage system according to claim 1, wherein the cooling system additionally comprises a fluid pump configured to circulate the coolant through the main coolant circuit. [6] Multi-cell rechargeable energy storage system according to claim 5, wherein the cooling system additionally includes a coolant cooler configured to remove thermal energy from the coolant in the main coolant circuit. [7] Multi-cell rechargeable energy storage system according to claim 6, wherein the cooling system additionally comprises a coolant heater configured to supply thermal energy to the coolant in the main coolant circuit. [8] Multi-cell rechargeable energy storage system according to claim 7, further comprising an electronic control system configured to regulate the operation of the at least one flow valve, the fluid pump, the coolant cooler and the coolant heater. [9] Multi-cell rechargeable energy storage system according to claim 8, wherein the electronic control is additionally configured to regulate the temperature of the individual battery modules by distributing the coolant via the at least one flow valve to the plurality of coolant branches. [10] Motor vehicle, comprising: an electric motor-generator configured to produce torque; a multi-cell rechargeable energy storage system, RESS, configured to supply electrical energy to the electric motor-generator, wherein the RESS includes: a large number of battery cells arranged in individual battery modules; and a cooling system, including: a main coolant circuit configured to circulate a coolant; a plurality of coolant branches arranged in parallel, each coolant branch being configured to receive a portion of the coolant from the main coolant circuit in order to remove thermal energy from one of the respective battery modules; and at least one flow valve configured to regulate the coolant circulating through the main coolant circuit and to distribute it to the multitude of coolant branches; and an electronic control configured to regulate the operation of at least one flow valve.

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