Ultra-high performance battery module with active and dynamic management of operating temperature and pressure

Abstract

A system and method for managing the operating temperature and pressure of a battery is disclosed. The cells of the battery are housed in a cylindrical module in which a pressurized heat transfer fluid at a certain temperature circulates. A fluidic unit has a reflux tank that collects the oil leaving the module, and cooling and heating tanks that contain the oil pumped from the reflux tank at predefined high and low temperatures. The oil is delivered to the module at a temperature and pressure that is obtained almost instantaneously by adjusting the mixture and flow rate of the hot and cold oil. The mixture and flow rate are controlled by a controller connected to a BMS, which manages the pressure and temperature set points of the oil applied to the cells depending on the power and energy demand received by the BMS and the pressure and temperature measurements taken by sensors in the system.

Description

[Technical field]

[0001] The present invention relates to a system and method for actively and dynamically managing the operating pressure and temperature of cells in one or more battery modules. [Background technology]

[0002] The values ​​of the operating pressure and temperature of lithium-ion cells cannot be used as a criterion for optimal operation of next-generation battery cells, including solid-state batteries. According to current knowledge, accurate, active and dynamic management of the values ​​of the operating pressure and temperature of batteries can be important for: - minimizing / eliminating the dynamic appearance of voids or "voids" during fast discharge (the "stripping" phase) which subsequently promote the formation of dendrites during fast charging; - Increasing the charging rate while limiting / eliminating the process of dendrite formation and propagation during "precipitation"; - Extending battery life (maintaining capacity and minimizing "dead" or inactive lithium); - limiting the rate of increase in impedance of a battery cell with charge / discharge cycling; - Work-hardened zones / tips of dendrites (increased diffusion / transport of lithium or other metals forming the anode), - ensuring that the contact quality of the cell's cathode-electrolyte-anode interface is maintained; - Minimizing / eliminating damage to cells in the event of abnormal demand; - Fully utilize the potential of next-generation batteries.

[0003] As is known in the art, WO 2019 / 017994 (Hettrich) proposes active and passive battery pressure management and battery modules in which a fluid maintains an isotropic pressure on at least one electrochemical cell in the module.

[0004] U.S. Patent Application Publication No. 2020 / 0259232 (Ge et al.) proposes a stable battery with high performance on demand, where the battery cells include heating elements such as resistors to increase the temperature of the battery and improve its performance.

[0005] US Patent Application Publication No. 2016 / 0380315 (Weicker et al.) proposes a battery system with a set of independently controlled battery cells based on specialized, complementary battery modules, e.g., a power-specialized module and an energy-specialized module. The module specificity may involve the use of different chemistries for each module.

[0006] US Patent Application Publication No. 2014 / 0227568 (Hermann) proposes a selectively thermally managed battery system that includes battery modules that work together such that one module heats another module as needed.

[0007] U.S. Patent Application Publication No. 2013 / 0330577 (Kristofek et al.) proposes dynamic pressure control of a battery assembly with a fluid that can also be used to manage temperature. The fluid is not in direct contact with the battery cells, but is contained in a pouch that contacts the cells, can cool the cells, and can apply pressure to the cells.

[0008] US Patent Application No. 2021 / 0167414 (Torres Martinez) proposes a pressurized electrochemical battery and a corresponding manufacturing method. A dynamic pressure and temperature management system is realized with a fluid fulfilling both roles, in a similar manner to that proposed in US Patent Application No. 2013 / 0330577.

[0009] German Patent Application No. 102019211729 (Jahnke et al.) proposes a vehicle battery module with a dynamic pressure management system. The mechanism for applying pressure to the battery cells can be passive or active, by means of springs, piezoelectric elements, or small pouches filled with fluid.

[0010] German patent application No. 102018203050 (Hoffmann) proposes a dynamic pressure management system for batteries, based on injecting a fluid into a pouch applied in contact with the cells of the battery.

[0011] None of the systems proposed in the art are able to actively and dynamically manage significant pressure and temperature variations at the cell level of the battery with near instantaneous response times in response to given operating or demand conditions in order to take advantage of the possible performance characteristics of such batteries. Summary of the Invention [Problem to be solved by the invention]

[0012] It is an object of the present invention to provide a system for managing the operating pressure and temperature of the cells of one or more battery modules, thereby making it possible to take advantage of the possible performance characteristics of such batteries. [Means for solving the problem]

[0013] According to one aspect of the present invention, there is provided a system for managing the operating pressure and temperature of a battery, the system comprising: at least one battery module having a chamber for housing cells of a battery and at least one on-board circuit connected to the cells and configured to control the operation of the cells and to monitor the state of charge of the cells, the chamber having opposed fluid inlets and fluid outlets for receiving and discharging a heat transfer fluid applied to all of the cells; a fluid unit having a reflux tank in communication with a fluid outlet of each battery module, a cooling tank containing a quantity of heat transfer fluid pumped from the reflux tank at a predefined low temperature, a heating tank containing a quantity of heat transfer fluid pumped from the reflux tank at a predefined high temperature, and a temperature and pressure regulation device having an inlet in communication with the cooling tank and the heating tank and at least one outlet in communication with a fluid inlet of each battery module for delivering the heat transfer fluid at a temperature and a pressure by controlling the mixing and flow rate of the heat transfer fluid led from the cooling tank and the heating tank; a temperature sensor and a pressure sensor for measuring the temperature and the pressure of a heat transfer fluid circulating between the fluid unit and the at least one battery module; at least one controller having an input for receiving a temperature setpoint signal and a pressure setpoint signal of the heat transfer fluid in the at least one battery module, an input for receiving a temperature measurement signal and a pressure measurement signal generated by the temperature sensor and a pressure measurement signal, and an output for generating a signal for controlling the mixture and the flow rate of the heat transfer fluid delivered by the fluidic unit according to the setpoint signal and the temperature measurement signal and the pressure measurement signal; a BMS connected to the at least one controller and the at least one on-board circuit, the BMS configured to generate temperature and pressure setpoint signals for a heat transfer fluid and a demand setpoint for the at least one battery module in response to energy and power demands received at an input and a state of charge provided by the at least one on-board circuit; and A system is provided, comprising:

[0014] According to another aspect of the present invention, there is provided a method of managing the operating pressure and temperature of a battery, the method comprising: - housing the cells of the battery in a chamber defined by at least one battery module, the chamber having opposed fluid inlets and fluid outlets for receiving and discharging a heat transfer fluid applied to all of the cells; monitoring the state of charge of cells in said at least one battery module; - collecting the heat transfer fluid discharged by the fluid outlet of each battery module into a reflux tank; - separately cooling and heating a quantity of heat transfer fluid pumped from a reflux tank to a cooling tank and a heating tank to predefined cold and hot temperatures; conveying a heat transfer fluid to a fluid inlet of the at least one battery module at a temperature and pressure regulated by controlling the mixture and flow rate of the heat transfer fluid conducted from the cooling and heating reservoirs; obtaining temperature and pressure measurements of a heat transfer fluid conveyed towards and discharged by the at least one battery module; controlling the mixture and flow rate of the heat transfer fluid delivered to the at least one battery module according to the measurements and temperature and pressure setpoints; adjusting a temperature set point and a pressure set point of a heat transfer fluid and a demand set point for the at least one battery module in response to energy and power demand and a state of charge of cells in the at least one battery module; A method is provided, comprising:

[0015] Without being limited thereto, the present invention relates to a system for managing the operating pressure and temperature of cells of one or more battery modules, and includes: arriving at a precise pressure value to be applied to the cells in response to battery demand conditions; applying uniform pressure to the battery cells; applying critical pressure values, e.g., pressure values ​​up to 2000 psi; very quickly changing the pressure value applied to the cells in response to changes in battery demand or operating conditions; cell volume changes during charge and discharge cycles; arriving at a precise temperature value for the cells in response to battery demand or operating conditions; very quickly changing the temperature value of the cells in response to changes in demand or operating conditions; applying critical temperature values ​​and changes (e.g., 0 to 80° C.); a system that allows simultaneously or separately to use a thermally stable battery in a vehicle; to obtain a uniform temperature in each of the cells over its entire surface; to adjust, by variable and / or scalable algorithms, pressure and temperature control strategies according to the state of health of the battery and specifics related to the use of the battery; to minimize the transmission of vehicle vibrations to the battery cells in order to maintain the integrity of the electrical contacts when the battery is used in a vehicle; to minimize the energy consumption for cooling or heating the heat transfer fluid and for applying the critical pressure; to integrate the various assemblies of the system into the vehicle body in a cost-effective manner; and to neutralize the chemical reaction in the event of a cell defect or accident.

[0016] Preferred embodiments will now be described in detail with reference to the following drawings: [Brief description of the drawings]

[0017] [Figure 1] 1 is a schematic diagram illustrating a system for managing the operating pressure and temperature of a battery, according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic diagram illustrating a pressure and temperature control device according to one embodiment of the present invention. [Diagram 3] 4 is a flow chart illustrating a system command and control process in accordance with one embodiment of the present invention. [Figure 4]4 is a flow chart illustrating parameters related to pressure and temperature management and operation of a battery module in accordance with one embodiment of the present invention. [Figure 5A-5D] 4 is a graph illustrating an example of a pressure and temperature management protocol implemented in a system according to an embodiment of the present invention. [Figure 6] FIG. 2 is an exploded schematic diagram of a battery module having button cells according to one embodiment of the present invention. [Figure 7A-7B] FIG. 2 is a partial perspective view of the internal structure of a battery module according to one embodiment of the present invention. [Figure 8A-8D] 1 is a schematic diagram of a possible configuration of several battery modules according to one embodiment of the present invention. [Figure 9A-9B] FIG. 2 is an exploded schematic diagram of a battery module having prismatic cells, according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] In the context of this disclosure, a battery is formed from cells that include two electrodes, a positive electrode (or cathode) and a negative electrode (or anode), separated by a medium that acts as an ion conductor, called the electrolyte. These cells may be of different architectures, formats, and dimensions. The anode, cathode, and electrolyte may be made of different materials. The electrolyte may be liquid, solid, or hybrid (polymer, ceramic, liquid, etc.).

[0019] As used in the context of this disclosure, the terms "near instantaneous" or "instantaneous" mean a time lapse or response time of about 15 seconds or less, unless the context requires otherwise.

[0020] With reference to FIG. 1, a system for managing the operating pressure and temperature of a battery according to an embodiment of the present invention is shown. The system comprises at least one battery module 2. In the illustrated case and in the following disclosure, for simplicity and simplicity, a system with three battery modules 2 is described. It is understood that the number of battery modules in the system may be different from one or three, for example, two or four or more, if desired. The present invention provides a solution to the problem of optimally using a battery by actively, dynamically, precisely, and almost instantly managing the operating pressure and temperature of the cells it contains, by a heat transfer fluid circulating through the system according to a control mode described below. In FIG. 1, the dotted lines represent the circulation lines of the heat transfer fluid, and the solid lines represent the signal communication lines.

[0021] With reference to FIG. 6, each battery module 2 has a chamber 4 that houses the cells 6 of the battery and at least one on-board circuit 8 connected to the cells 6 and configured to control the operation of the cells 6 and to monitor the state of charge of the cells 6. The on-board circuit(s) 8 may include a power unit, an energy sink, a current limiter, and a smart charger (not shown) to create relevant conditions of pressure, temperature, and current density to obtain optimal performance from the battery module 2. The chamber 4 has a fluid inlet 10 and a fluid outlet 12 (e.g., as shown in FIG. 2) on opposite sides to receive and discharge a heat transfer fluid applied to all the cells 6. Preferably, the heat transfer fluid is a liquid, advantageously an oil, and more advantageously a mineral oil that can neutralize potential chemical reactions in case of defective or damaged cells. In the following disclosure, the term "hydraulic" may be used instead of "fluid" with respect to the oil used as the heat transfer fluid, without limiting the heat transfer fluid to oil only, or limiting the pressure and temperature regulation device to oil only.

[0022] Referring again to FIG. 1, the system includes a return tank 16 in communication with the fluid outlet 12 (e.g., as shown in FIG. 2) of each battery module 2, a cooling tank 18 containing a quantity of heat transfer fluid pumped from the return tank 16 at a predefined low temperature, a heating tank 20 containing a quantity of heat transfer fluid pumped from the return tank 16 at a predefined high temperature, and a fluid unit 14 having a temperature regulation device 22 and a pressure regulation device 24 having an inlet 26 in communication with the cooling tank 18 and the heating tank 20 and at least one outlet 28 in communication with the fluid inlet 10 of each battery module 2 to deliver the heat transfer fluid at a desired temperature and pressure by controlling the mixing and flow rate of the heat transfer fluid led from the cooling tank 18 and the heating tank 20. According to one embodiment, the predefined high temperature is 100° C. and the predefined low temperature is −30° C., so that the heat transfer fluid supplied by the fluidic unit 14 to the battery module 2 can have, thanks to dynamic management, an almost instantaneous change in temperature from −30° C. to 100° C. Depending on the chemistry of the battery module 2 used and its operating temperature range, other low and high temperature values ​​may also be appropriate, for example preferably up to 0° C. and 80° C.

[0023] 2, the system comprises temperature sensors 31 (T1, T2, T3) and pressure sensors 33 (P1, P2, P3) for sensing the temperature and pressure of the heat transfer fluid circulating between the fluidic unit 14 and the battery module 2. According to one embodiment of the invention, the system comprises controllers 34, 36, 38 (hereinafter also referred to as controllers #1, #2, #3) having inputs 40, 42, 44 for receiving temperature and pressure setpoint signals of the heat transfer fluid in the battery module 2, inputs 46, 48 for receiving temperature measurement signals T1, T2, T3 and pressure measurement signals P1, P2, P3 generated by the temperature and pressure sensors 31 and 33, and an output 50 for generating signals for controlling the mixture and flow rate of the heat transfer fluid delivered by the fluidic unit 14 according to the setpoint signals and the temperature and pressure measurement signals. The functions of the controllers 34, 36, 38 may be performed by a single controller if desired. Other types of sensors may also be added to the system to allow for monitoring, measurement, notification, adjustment, regulation, and release, such as sensors that measure current, sensors that measure voltage, and sensors that analyze gases dissolved in the oil or other heat transfer fluid used (not shown).

[0024] 1, the system includes a BMS 52 connected to the controllers 34, 36, 38 (e.g., as shown in FIG. 2) and the on-board circuitry 8 of the battery module 2 (e.g., as shown in FIG. 6). The BMS 52 is configured to generate temperature and pressure setpoint signals for the heat transfer fluid and one or more demand setpoints 54 for the battery module 2 in response to energy and power demands received at input 56 and a state of charge provided by the on-board circuitry 8.

[0025] The BMS 52 may be configured to store and execute algorithms that control the operating parameters of the battery modules 2 in response to the demand state, charge state, and health state of the battery modules 2, and in response to the ambient temperature and a predefined mission of the battery modules of the battery modules 2. The demand state, charge state, and health state may be transmitted to the BMS 52 via a controller 88 that controls the demand setpoint of the battery modules. The charge state and health state are provided by a monitoring module 90 that processes signals generated by the on-board circuitry 8 of the battery modules 2 (e.g., as shown in FIG. 6). The predefined mission of the battery modules 2 may be programmed in the BMS 52 such that the BMS 52 generates appropriate command and control signals in response to the mission, via the controller 88 and circuitry 54 that communicate with the on-board circuitry 8 of the battery modules 2, and via the pressure control controller 36 and the temperature control controllers 34, 38, to dynamically and actively manage its pressure, its temperature, its demand usage, and its status. The mission of the battery modules 2 may, for example, be to operate its cells 6 in a different way than they are normally designed. The operating parameters can include the pressure and temperature of the heat transfer fluid circulating in the battery modules 2, and can also include the power tolerated by each battery module 2. Demand conditions can be, for example, fast charging, power demands, for example in the case of an electric vehicle, acceleration, load pulling, heavy braking.

[0026] The system may be provided with a heat exchanger 92 for exchanging heat with each tank 16, 18, 20 of the fluid unit 14, and peripheral devices (not shown) that generate thermal energy, such as heating devices, air conditioners, brake motors, smart chargers, etc., to minimize energy consumption for heating / cooling the heat transfer fluid.

[0027] Referring again to Fig. 2, according to an embodiment, the fluidic unit 14 comprises a pump 94 and an accumulator 100, which allow to dynamically adjust and manage the pressure applied to the battery module 2 to a desired value. The pump 94 has an inlet 96 communicating with the reflux tank 16 and an outlet 98 for delivering a quantity of heat transfer fluid pumped from the reflux tank 16. The accumulator 100 has an inlet 102 communicating with the outlet 98 of the pump 94 and an outlet 104 communicating with the cooling tank 18 and the heating tank 20. The accumulator 100 generates a control signal 106 for controlling the pump 94 in such a way that the pressure of the heat transfer fluid in the cooling tank 18 and the heating tank 20 is slightly higher than the pressure set point 44 according to a pressure measurement provided by a pressure sensor 103 (P0) at the outlet 104 of the accumulator 100. A pressure relief valve 108 is preferably added in parallel with the pump 94.

[0028] Referring again to FIG. 6, each battery module 2 may be formed from a tubular element 58 and end elements 60, 62 that close the tubular element 58 to define a tank-like chamber 4. A structure 64 supporting and spacing the cells 6 axially of the tubular element 58 may advantageously ensure proper spacing of the cells 6 to allow for volumetric changes of the cells 6 during charge / discharge cycles and to minimize the transmission of mechanical vibrations to the cells 6 immersed in the heat transfer fluid. A heat transfer fluid distributor 66 has openings 68 (e.g., as shown in FIG. 7B) in communication with the fluid inlet 10 and aligned with the spaces between the cells 6. A wiring device 70 connects the cells 6 and the on-board circuit(s) 8 together. The tubular element 58 may have a cylindrical shape as shown in FIG. 6. The cylindrical shape is particularly well suited for the button-type cells 6, which are also shown in this figure. The end elements 60, 62 may advantageously have a cup shape protruding at the opposite ends of the tubular element 58 and defining an internal space for accommodating the on-board circuit(s) 8. In the case of two on-board circuits 8 (only one is visible in FIG. 6), they are accommodated in end elements 60, 62, respectively, and insulated from the bath or chamber 4 by sealing washers 110, 112. Cylindrical tubular elements may also be used for the construction of prismatic cells 6, as shown in FIG. 9B. The structures 64 for supporting and spacing the cells 6, the distribution device 66, and the wiring device 70 (as shown in FIG. 6) are then suitably modified, for example by suitable elements (not shown) arranged between successive stacks of cells 6 and at the opposite ends of the tubular element 58. The tubular element 58 may also have a parallelepiped shape, which may be advantageously suited to prismatic cells 6, as shown in FIG. 9B, or may have another shape, such as an oblong shape, if desired. Likewise, shapes other than cups can be used for the end elements 60, 62, if desired. Opposite ends of the end elements 60, 62 and the tubular element 58 can advantageously present flanges 59 for assembly by bolts (not shown), allowing the battery module 2 to be removed as required. Other types of connectors and assemblies can be used, if desired.

[0029] 7A and 7B, according to one embodiment, the supporting and spacing structure 64 comprises an elongated rod 72 having an outer surface substantially conforming to the inner surface of the cylindrical element 58 (e.g., as shown in FIG. 6) and an inner surface presenting a transverse notch 74 arranged axially of the cylindrical element 58 and engaging with a periphery 76 of the cell 6. The distributor 66 may comprise a conduit 78 extending into the rod 72 and communicating with the fluid inlet 10 (e.g., as shown in FIG. 6), the opening 68 of the distributor 66 being made on the inner surface of the rod 72 such that the heat transfer fluid exerts an isotropic (uniform) pressure on the cells 6 immersed in the heat transfer fluid and in direct contact with the heat transfer fluid. The wiring device 70 may be formed by a series of upper and lower pads 80, 82 electrically connected to each other and in contact with the electrodes of the cells 6. The upper series of pads 80 may extend between the rods 72. The above-described configuration of the battery module 2 allows optimal circulation of the heat transfer fluid (fast temperature changes, uniform temperature of the cells).

[0030] 2, the heat transfer fluid circulates between the fluidic unit 14 and the battery modules 2 through pipe circuits (shown by thick black lines) provided with devices for flow control of the heat transfer fluid controlled by controllers 34, 36, 38 to regulate the temperature and pressure of the heat transfer fluid circulating in the pipe circuits. The flow control devices may advantageously be, for each battery module 2, distributors D1, D2, D3 of the heat transfer fluid delivered to the battery module 2 and proportional pressure limiters L1, L2, L3 of the heat transfer fluid discharged by the battery module 2.

[0031] According to one embodiment, the controller 34 (#1) is used as a controller for temperature management of the heat transfer fluid in the system as a whole, for example by controlling the flow regulation devices formed by the distributors D4, D5 on the fluid lines 30, 32 associated with the cooling bath 18 and the heating bath 20 according to a temperature setpoint signal received at the input 40. The controller 34 may have an input 84 for receiving and taking into account a temperature regulation signal derived from a temperature sensor 35 (T0), which indicates the temperature of the heat transfer fluid delivered by the fluid unit 14. The controller 36 (#2) is used as a controller for pressure management of the heat transfer fluid delivered to and discharged from the battery module 2, by controlling the distributors D1, D2, D3 and the proportional pressure limiters L1, L2, L3 according to a pressure setpoint signal 44 and a pressure measurement signal (P1, P2, P3) provided by the sensor 33. In this way, the controller 36 is responsible for controlling the pressure of the heat transfer fluid in the battery module 2. The controller 36 is connected to a pressure sensor 37 (P 0’ ) may have an input 86 for receiving and taking into account a signal derived from the temperature sensor 31. The controller 38 (#3) is used as a controller for temperature management of the heat transfer fluid circulating in particular in the battery module 2 by controlling the distributors D1, D2, D3 carrying the heat transfer fluid to the battery module 2 according to a temperature setpoint signal 42 at the level of the cells 6 of the battery module 2 and temperature measurement signals (T1, T2, T3) provided by the temperature sensor 31. The controller 38 also provides a temperature setpoint to the controller 34 managing the fluidic unit 14.

[0032] With reference to Figures 8A, 8B, 8C, and 8D, the battery modules 2 may be configured to form independent, complementary, or combined configurations depending on whether the fluid inlets 10 and outlets 12 are combined or separated, and depending on the chemistry of the cells of the battery modules 2. For example, each battery module 2 may operate independently in pressure and temperature, as shown in Figure 8A. The battery modules 2 may operate at a common pressure but different temperatures, as shown in Figure 8B. Some battery modules 2 may operate at a common pressure different from the pressure of the other battery modules 2, but at different temperatures for each battery module 2, as shown in Figure 8C. Some battery modules 2 may operate at a common pressure and temperature different from the operating pressure and operating temperature of the other battery modules 2, as shown in Figure 8D. The design of the battery modules 2 may be selected depending on the particular operating conditions, e.g., in the case of an electric vehicle (not shown), very fast charging, high acceleration, or significant payload to be towed, storage, extreme outside temperatures, and depending on the application for which they are intended, e.g., automobile, truck, bus, airplane, train, boat, energy storage. Battery modules 2 can be used in any number desired, in various capacities and dimensions, whether complementary or not, combined or not. The pressure and temperature values ​​of the battery modules 2 can be adjusted in real time or fixed. Even if one of the battery modules 2 has to be replaced after a certain time (e.g. sooner than usual), it may be intended to play a special role (i.e. its mission), for example to operate at a certain pressure, especially at a very high pressure to deal with extreme operating conditions such as very fast charging, or to be called on preferentially during high acceleration in the case of an electric vehicle. Such a battery module 2 may also be likened to a sacrificial battery module for performance improvement.In one embodiment of the present invention, the system may include a battery module 2 in which pressure regulation is achieved solely by fluctuations in the temperature of the heat transfer fluid, by utilizing the effect of the thermal expansion coefficient of the heat transfer fluid, particularly when higher pressure values ​​are required for higher temperature values.

[0033] To summarise, with reference again to FIG. 1, according to one embodiment of the present invention, the system comprises at least one battery module 2 (or several cooperating battery modules 2) with variable or fixed operating conditions (variable or dedicated role), with active and dynamic management of the operating temperature and pressure applied to the cells 6 (for example as shown in FIG. 6) via a liquid (or fluid) under pressure in which the cells 6 are immersed. The various mechanical, hydraulic, electrical and logical systems mentioned above are controlled by a processor (not shown, but which may be integrated in the BMS 56 or in the controllers 34, 36, 38) which is controlled by a scalable and coordinated algorithm via a master software implemented in the BMS 56. The BMS 56 may execute smart charging management algorithms, including efficient and optimal management strategies (pressure and temperature regulation) of the energy consuming systems during fast charging or hard braking. The scalable algorithms may be based on the implementation of artificial intelligence. By actively and dynamically managing the operating temperature and pressure applied to the cells 6, the cells of the battery can be optimally used. The elements 58, 60, 62 of the battery module 2 (e.g., as shown in FIG. 6) form a cylindrical tank that is compact and easy to install in a vehicle (not shown), while allowing the cells 6 to be subjected to variable and high isostatic pressures (e.g., up to 2000 psi).

[0034] According to one embodiment of the present invention, a method for managing the operating pressure and temperature of a battery includes housing the cells 6 of the battery in a chamber 4 defined by at least one battery module 2, the chamber having opposing fluid inlets 10 and fluid outlets 12 for receiving and discharging a heat transfer fluid applied to all the cells 6. The method also includes monitoring the state of charge of the cells 6 of each battery module 2, collecting the heat transfer fluid discharged by the fluid outlets 12 of each battery module 2 in a reflux tank 16, separately cooling and heating a quantity of heat transfer fluid pumped from the reflux tank 16 to a cooling tank 18 and a heating tank 20 at a predefined low temperature and a predefined high temperature, and conveying the heat transfer fluid to the fluid inlet 10 of each battery module 2 at a temperature and pressure regulated by controlling the mixture and flow rate of the heat transfer fluid led from the cooling tank 18 and the heating tank 20. The method further includes obtaining temperature and pressure measurements of the heat transfer fluid delivered to and discharged by each battery module 2, controlling the mixture and flow rate of the heat transfer fluid delivered to each battery module 2 according to the measurements and the temperature and pressure setpoints, and adjusting the temperature and pressure setpoints of the heat transfer fluid and the demand setpoint for each battery module 2 according to the energy and power demand and the state of charge of the cells 6 in each battery module 2. According to an embodiment, the flow rate of the heat transfer fluid delivered to each battery module 2 is maintained as long as the pressure and temperature measurements differ from the pressure and temperature setpoints. The method may include executing a scalable process to dictate the operating parameters of each battery module 2 according to the demand, state of charge, and state of health of each battery module 2, as well as the ambient temperature and the predefined mission of the battery module 2 among all battery modules 2 used.

[0035] In the following description, the heat transfer fluid is considered to be oil, however, it will be understood that other fluids suitable for the present invention may be used at different temperature ranges if desired.

[0036] Referring to FIG. 3, according to one embodiment, the temperature setpoint of the oil (mixture) 114 is based on the operating temperature setpoint (e.g., −30° C. to 100° C., or other preferred temperature range) of the cells 6 (e.g., as shown in FIG. 6 ), taking into account heat losses, thermal inertia, the volume of oil in operation, the allowable time to reach the new operating temperature value, and material-related considerations (e.g., allowed thermal transitions). A strategy for quickly reaching the oil temperature setpoint can be based on lab-developed algorithms 116, 118, 120, 122 for the required hot-cold mixture (flow rate). Prioritization by the BMS 52 can be performed for the ordering to reach the setpoints when different operating temperatures are required between the battery modules 2. The sizing of the components of the system (e.g., each of the tanks 16, 18, 20, pump 94, accumulator 100, battery modules shown in FIG. 2 ) is preferably optimized to maximize the speed of changing the temperature of the cells 6. Regarding pressure regulation, first the oil is at the correct temperature, and the pressure set point 124 can be achieved simultaneously for all battery modules 2, even if the set points are different for each battery module 2. The controller #2 36 can operate the pressure limiters L1, L2, L3 and servo valves D1, D2, D3 (e.g., as shown in FIG. 2) of the battery modules 2 to regulate their pressures 126, 128. The interaction between the processes of regulating the oil temperature and pressure can include maintaining the oil flow rate unless both set points (temperature and pressure) are reached. The set point for reaching the pressure can also take into account the effect of two other factors on the pressure value, namely, the oil temperature and the variable volume of the cells (state of charge) 130. If the temperature and pressure set points are reached, the battery module 2 is considered to be in compliance 132, otherwise the temperature of the battery module 2 is again corrected 116.

[0037] Referring again to FIG. 2, when the BMS 52 (e.g., as shown in FIG. 1) transmits set points for adjusting the operating pressure and temperature of the cells 6 (e.g., as shown in FIG. 6) to appropriately adjust the usage conditions according to their demand conditions, the limiting pressure set points are transmitted to the pressure limiters L1, L2, L3 via the controller #2 36 to obtain the target operating pressures P1, P2, P3 in the battery modules 2 (#1, #2, and #3). If the new pressure set point of a given battery module 2 is higher than the pressure measured in the battery module 2, the distributor D1, D2, or D3 associated with the battery module 2 (#1, #2, or #3), via the controller 36 (#2), allows the intake of oil to make it possible to reach this new pressure value. The new pressure value is reached instantaneously. The pressure P of the accumulator 100 is A can generate a pressure P0 in the low-temperature oil tank 18 and the high-temperature oil tank 20. When the oil mixing is performed, a pressure P 0’ To instantly create the desired pressure in the battery module 2, Amin >P0>P 0’ >P1, P2, P3. For example, if the maximum pressure of the module is set to 1,000 psi, the minimum allowable pressure of the accumulator 100 may be 1,500 psi. Amin When the value of P falls below the 1500 psi threshold, pump 94 is started and AmaxOil is injected into the accumulator 100 until it reaches a value (e.g., 2500 psi). When the operating temperature set points T1, T2, and T3 of the cell 6 are transmitted by the BMS 52, the controller 34 (#1) manages the line distributors D4 and D5 of the cold and hot oil according to a flow management algorithm to generate an oil mixture at temperature T0. To increase the operating temperature value of the cell 6, T0 > T1, T2, T3. Conversely, to decrease the operating temperature value of the cell, T0 < T1, T2, T3. The difference in values between the temperature T0 of the oil mixture and the operating temperatures T1, T2, T3 of the cell 6 depends on the speed at which the new operating temperature is reached, taking into account the thermal inertia of the entire system and the limits of heat transfer allowed by the materials forming the cell 6. Even when the operating pressure values P1, P2, and P3 are reached for a given battery module 2, the controller 38 (#3) enables the oil intake at T0 via the distributors D1, D2, and D3 associated with the battery module 2 as long as the target operating temperatures T1, T2, and T3 of the battery module 2 have not been reached.

[0038] With reference to FIG. 4, an example of the advanced management that the system according to the invention may perform according to different parameters of pressure and temperature management and operation of the battery module 2 is shown. An event 134, such as power demand, heavy braking, or fast charging, is notified to the BMS 52 (for example, as shown in FIG. 1). As shown in block 136, the BMS 52 performs an analysis of the system parameters versus the usage requirements. For this purpose, as shown in block 138, the BMS 52 may take into account certain conditions such as the state of charge (SOC), state of health (SOH), pressure and temperature of the cells 6 (for example, as shown in FIG. 6), their life history (calendar), and the number of cycles experienced by the cells 6 of the battery module 2. Similarly, the BMS 52 may take into account various parameters such as the ambient temperature, expected charging time, expected charging power, active peripheral devices, the type of terrain traveled, driving habits, driving mode selection, traffic conditions, charging options on the road, as shown in block 140. Then, a verification 142 is performed to determine whether the battery module 2 complies with the requirements with respect to the system parameters. If so, a power setpoint is sent to the matching battery module 2, as shown in block 144. If not, the BMS 52 sends the setpoint to the regulation mechanism, as shown in block 146. Regulation of temperature 148, regulation of pressure 150, and management of current density 152 are performed, ultimately resulting in a matching battery module 2 154. Power surplus management 156 can be performed for oil heating or cooling 158, for use of the battery module 2 as a sacrificial module at the expense of its normal operating parameters 160, or for power dissipation 162, if desired.

[0039] 5A, 5B, 5C, and 5D, examples of pressure and temperature management protocols implemented in a system according to an embodiment of the present invention are shown in graphical form. FIG. 5A shows a possible pressure regulation protocol for a cell 6 of a battery module 2 (e.g., as shown in FIG. 6) as a function of a recommended charge / discharge rate. FIG. 5B shows a possible pressure regulation protocol for a cell 6 of a battery module 2 as a function of its state of charge (SOC). FIG. 5C shows a possible operating temperature regulation protocol in terms of a recommended charge / discharge rate. FIG. 5D shows a possible operating pressure regulation protocol in terms of the number of charge / discharge cycles experienced by the battery module 2.

[0040] Referring again to FIG. 1, certain considerations may be relevant in relation to the system according to the invention. For example, the value of the oil pressure in the pressurized tank tends to vary depending on the following factors: pressure setpoint imposed by the BMS 52 on the fluidic unit 14, oil temperature variations, volume variations of the cells 6. The pressure regulation control algorithm may include regulated inputs related to these factors, based on a model integrating the interaction of the pressure setpoint and the temperature setpoint, and feedback regarding the state of charge of the cells 6 and thus their volume at a particular time. The BMS 52 may regulate and direct the use of the different battery modules 2 depending on the energy and power demand. The close management of each of the battery modules 2 may be performed by an on-board BMS or a BMS module implemented by the on-board circuitry 8, on board of each battery module 2. For example, oil monitoring, including monitoring of chemical elements or dissolved gases, may identify signs of degradation of the components forming the battery module 2. By using mineral oil as heat transfer fluid, potential chemical reactions may be neutralized if the cells 6 are defective or damaged. Implementing scalable algorithms, e.g. artificial intelligence, in the BMS 52 may represent a strategic aspect in using the system according to the invention. Such algorithms may be responsible for managing the operating parameters (current, pressure, temperature) of the battery module 2. The programming of initial algorithms (e.g. in industry) in the BMS 52 may be made depending on the application of the battery module 2 (e.g. automobile, bus, truck, aircraft, boat, storage, etc.). Modifications of such algorithms may be made over time depending on various factors such as type of driving (e.g. acceleration, braking, load towing), terrain morphology, outside temperature, charging patterns, usage patterns (frequency, duration), etc. The scalable algorithms may lead to a decision to overuse the battery module 2 in case of extreme usage situations (e.g. sacrificial module).It may also derive a specific charging scheme that includes a dendrite damage repair procedure ("self-healing") through a strategic combination of temperature-pressure-current values ​​and charging current patterns known to have a beneficial effect on the battery's condition (in response to power demand / charging rate, degraded performance of battery module 2, suspected presence of dendrite initiation zones).

[0041] While embodiments of the present invention have been illustrated and described above in the accompanying drawings, it will be apparent to those skilled in the art that modifications may be made without departing from the invention.

Claims

1. 1. A system for managing an operating pressure and an operating temperature of a battery, the system comprising: at least one battery module having a chamber for housing cells of the battery and at least one on-board circuit connected to the cells and configured to control operation of the cells and monitor a state of charge of the cells, the chamber having opposed fluid inlets and fluid outlets for receiving and discharging a heat transfer fluid applied to all of the cells; a fluid unit including a reflux tank in communication with the fluid outlet of each battery module, a cooling tank containing a quantity of the heat transfer fluid pumped from the reflux tank at a predefined low temperature, a heating tank containing a quantity of the heat transfer fluid pumped from the reflux tank at a predefined high temperature, and a temperature and pressure regulation device having an inlet in communication with the cooling tank and the heating tank and at least one outlet in communication with the fluid inlet of each battery module to deliver the heat transfer fluid at a certain temperature and a certain pressure by controlling the mixing and flow rate of the heat transfer fluid led from the cooling tank and the heating tank; a temperature sensor and a pressure sensor for measuring a temperature and a pressure of the heat transfer fluid circulating between the fluid unit and the at least one battery module; at least one controller having an input for receiving a temperature setpoint signal and a pressure setpoint signal of the heat transfer fluid in the at least one battery module, an input for receiving a temperature measurement signal and a pressure measurement signal generated by the temperature sensor and the pressure sensor, and an output for generating a signal for controlling the mixture and the flow rate of the heat transfer fluid pumped by the fluidic unit according to the setpoint signal and the temperature measurement signal and the pressure measurement signal; a BMS connected to the at least one controller and the at least one on-board circuit, the BMS configured to generate the temperature and pressure setpoint signals for the heat transfer fluid and a demand setpoint for the at least one battery module in response to energy and power demands received at an input and the state of charge provided by the at least one on-board circuit; A system comprising:

2. 2. The system of claim 1, wherein the cells of the at least one battery module are immersed in and in direct contact with the heat transfer fluid, the heat transfer fluid exerting an isotropic pressure on the cells.

3. The system of claim 1 , wherein the heat transfer fluid is oil.

4. The at least one battery module is a tubular element and an end element closing said tubular element to define said chamber; a structure supporting and spacing the cells axially along the tubular element; a distributor for the heat transfer fluid having an opening in communication with the fluid inlet and aligned with the space between the cells; a wiring arrangement connecting the cells and the at least one on-board circuit; The system of claim 1 , comprising:

5. The system of claim 4 , wherein the end elements protrude from opposite ends of the tubular element and have a cup shape defining an interior space that houses the at least one on-board circuit.

6. the structure supporting and spacing the cells comprises an elongate bar having an outer surface substantially conforming to an inner surface of the tubular element and an inner surface presenting transverse notches disposed in the axial direction of the tubular element and in which the peripheries of the cells engage; the distributor comprises a conduit extending into the rod and in communication with the fluid inlet, the opening of the distributor being formed on the inner surface of the rod such that the heat transfer fluid exerts an isotropic pressure on the cells; 5. The system of claim 4, wherein the wiring device comprises upper and lower pads electrically connected to each other and in contact with electrodes of the cells, the upper set of pads extending between the bars, and the at least one on-board circuit comprising two on-board circuits housed in the end elements.

7. 2. The system of claim 1, wherein the heat transfer fluid circulates between the fluid inlet and the at least one battery module through the pipe circuit comprising a device for regulating a flow rate of the heat transfer fluid controlled by the at least one controller to regulate a temperature and pressure of the heat transfer fluid circulating through the pipe circuit.

8. 8. The system of claim 7, wherein the device for regulating flow rate comprises, for each battery module, a distributor of the heat transfer fluid delivered to the battery module and a proportional pressure limiter of the heat transfer fluid discharged by the battery module.

9. The at least one controller: a first controller for temperature management of the heat transfer fluid, the first controller controlling flow regulating devices on fluid lines associated with the cooling bath and the heating bath according to a temperature setpoint; a second controller for pressure management of the heat transfer fluid circulating in the at least one battery module, which controls a flow regulation device of the heat transfer fluid delivered to and discharged by the at least one battery module according to the pressure set point signal and the pressure measurement signal; a third controller for temperature management of the heat transfer fluid circulating in the at least one battery module, controlling the flow regulation device of the heat transfer fluid conveyed to the at least one battery module according to the temperature setpoint signal and the temperature measurement signal; The system of claim 1 , comprising:

10. 2. The system of claim 1, wherein the at least one battery module comprises several battery modules that form independent, complementary or combined devices depending on whether their fluid inlets and fluid outlets are combined or separate and depending on the chemistry of their cells.

11. 2. The system of claim 1, wherein the BMS is configured to store and execute scalable algorithms for commanding operating parameters of the at least one battery module in response to demand, state of charge, and state of health of the at least one battery module, and in response to an ambient temperature and a predetermined mission of one of the at least one battery modules.

12. the operating parameters include the pressure and the temperature of the heat transfer fluid circulating in the at least one battery module and the power allowed by the at least one battery module; The system of claim 11 , wherein the demand conditions include fast charging and power demand.

13. The system of claim 2 , further comprising a heat exchanger associated with the reservoir of the fluidic unit and a peripheral device that generates thermal energy.

14. 2. The system of claim 1, wherein the predefined high temperature is between 80°C and 100°C and the predefined low temperature is between -30°C and 0°C.

15. The fluid unit comprises: a pump having an inlet in communication with the reflux vessel and an outlet for delivering a quantity of the heat transfer fluid pumped from the reflux vessel; an accumulator having an inlet communicating with the outlet of the pump and an outlet communicating with the cooling tank and the heating tank, the accumulator generating a control signal for controlling the pump such that the pressure of the heat transfer fluid in the cooling tank and the heating tank is slightly higher than the pressure set point according to a pressure measurement provided by a pressure sensor at the outlet of the accumulator; The system of claim 1 , comprising:

16. 1. A method for managing an operating pressure and temperature of a battery, the method comprising: housing cells of the battery in a chamber defined by at least one battery module, the chamber having opposed fluid inlets and fluid outlets for receiving and discharging a heat transfer fluid applied to all of the cells; monitoring the state of charge of the cells in the at least one battery module; collecting the heat transfer fluid discharged by the fluid outlet of each battery module into a reflux tank; separately cooling and heating a quantity of the heat transfer fluid pumped from the reflux tank to a cooling tank and a heating tank to predefined cold and hot temperatures; conveying the heat transfer fluid to the fluid inlet of the at least one battery module at a temperature and pressure regulated by controlling the mixture and flow rate of the heat transfer fluid channeled from the cooling reservoir and the heating reservoir; obtaining temperature and pressure measurements of the heat transfer fluid conveyed towards and discharged by the at least one battery module; controlling the mixture and the flow rate of the heat transfer fluid delivered to the at least one battery module according to the measurements and temperature and pressure setpoints; adjusting the temperature and pressure set points of the heat transfer fluid and a demand set point for the at least one battery module in response to energy and power demand and the state of charge of the cells in the at least one battery module; A method comprising:

17. 17. The method of claim 16, wherein the flow rate of the heat transfer fluid delivered to the at least one battery module is maintained as long as the pressure and temperature measurements differ from the pressure and temperature setpoints.

18. 17. The method of claim 16, further comprising executing a scalable process for dictating operating parameters of the at least one battery module in response to a demand, a state of charge, and a state of health of the at least one battery module, and in response to an ambient temperature and a predetermined mission of one of the at least one battery modules.

19. 17. The method of claim 16, wherein the cells of the at least one battery module are immersed in and in direct contact with the heat transfer fluid, the heat transfer fluid exerting an isostatic pressure on the cells.

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