Multi-layer sheets with flow channels

Abstract

A cooling panel for a battery system comprises a first sheet, a second sheet, and an additional sheet that overlap to form a multilayer sheet. The first sheet, the second sheet, and the additional sheet have hole patterns that partially overlap to form a flow channel through the multilayer sheet. A fluid flows through the flow channel of the multilayer sheet in contact with the battery module. The fluid absorbs heat from the battery module, thereby facilitating a safe operating environment for the battery modules. The first sheet, the second sheet, and the additional sheet are made of a flexible and porous nonwoven material. The multilayer sheet may be on one side of the battery cells or may surround the battery cells of the battery module of an electric vehicle.

Description

Technology Field

[0001] The present disclosure relates to multilayer sheets having fluid channels. Background Technology

[0002] This section provides background information related to the present disclosure, which is not necessarily prior art.

[0003] The present disclosure provides an efficient and effective method for reducing heat from battery cells for electric vehicles or other devices using battery cells.

[0004] The purpose of multilayer sheets having flow channels is to provide and maintain a safe, optimal operating temperature for the battery cells of electric vehicles. By forming a safe, optimal environment for battery cell operation, multilayer sheets with flow channels facilitate the flow of fluids that absorb heat from the battery cells to extend their lifespan.

[0005] Previous heat exchange devices or battery cooling plates, which facilitate the flow of fluids absorbing heat from battery cells, are heavy and rigid structures. The additional weight of heat exchangers or battery cooling plates reduces the mileage range of electric vehicles. The rigidity of heat exchangers or battery cooling plates requires additional labor time for the formation, manufacturing, and assembly of tolerance stacking analysis in electric vehicles. Furthermore, the additional weight of rigid battery cooling plates and the reduced mileage range of electric vehicles create environmental impacts through the continuous need to recharge the vehicles. Therefore, it is desirable to reduce weight and simplify the structure, manufacturability, and assembly of heat exchangers and battery cooling devices.

[0006] This section provides a general summary of the present disclosure and is not a comprehensive disclosure of the full scope or all features thereof.

[0007] According to an aspect of the present disclosure, a cooling panel for a battery system comprises a first sheet having a first hole pattern, a second sheet having a second hole pattern that is different from or offset from the first hole pattern, and at least one additional sheet having a third hole pattern that is different from the second hole pattern, wherein the first sheet, the second sheet, and at least one additional sheet overlap to form a multilayer sheet, and the first hole pattern of the first sheet, the second hole pattern of the second sheet, and the third hole pattern of at least one additional sheet partially overlap to form a flow channel.

[0008] According to an additional embodiment, the first sheet, the second sheet, and at least one additional sheet have a thickness of 50 microns to 2000 microns. The thicknesses of the different sheets may vary.

[0009] According to an additional embodiment, the multilayer sheet is directly connected to a battery system, a battery module, a single battery cell, or an electronic device.

[0010] According to an additional embodiment, the multilayer sheet has an external container.

[0011] According to an additional embodiment, the fluid flows through a flow channel.

[0012] According to an additional embodiment, the first sheet, the second sheet, and at least one additional sheet are made of a nonwoven material, other fibrous fabric, plastic, metal, rubber, or open porous foam.

[0013] According to an additional embodiment, the nonwoven material may have open porosity. The porosity may be within the plane and through the plane to allow the coolant to come into contact with the heat source and the cooling device or heat sink.

[0014] According to an additional embodiment, the first hole pattern of the first sheet, the second hole pattern of the second sheet, and the third hole pattern of at least one additional sheet comprise material removed from the thin sheet material.

[0015] According to an additional embodiment, the material removed from the nonwoven material can be cut by laser cutting, punching, or other methods.

[0016] According to an embodiment of the present disclosure, a cooling panel for a battery system comprises a battery module having a plurality of battery cells, a first sheet having a first hole pattern, a second sheet having a second hole pattern different from or offset from the first hole pattern, and at least one additional sheet having a third hole pattern different from the second hole pattern, wherein the first sheet, the second sheet, and at least one additional sheet overlap each other to form a multilayer sheet, and the first hole pattern of the first sheet, the second hole pattern of the second sheet, and the third hole pattern of at least one additional sheet partially overlap to form a flow channel through the multilayer sheet, and the multilayer sheet contacts the battery module.

[0017] According to an additional embodiment, the first sheet, the second sheet, and at least one additional sheet have a thickness of 50 microns to 2000 microns.

[0018] According to an additional embodiment, the first sheet, the second sheet, and at least one additional sheet are made of a nonwoven material.

[0019] According to an additional embodiment, the nonwoven material may be porous.

[0020] According to an additional embodiment, at least one of the sheets may be electrically isolated to isolate the cells from each other. For example, by using a central layer or two outer layers in a three-layer arrangement, increased heat transfer between cell surfaces can be obtained.

[0021] According to an additional embodiment, the battery module has an external container that encapsulates multiple battery cells.

[0022] According to an additional embodiment, the fluid flows through the fluid inlet of the external container.

[0023] According to an additional embodiment, the fluid flowing through the inlet of the external container flows through the flow channel of the multilayer sheet.

[0024] According to an additional embodiment, a fluid flowing through the fluid inlet of an external container and through the flow channel of a multilayer sheet absorbs heat from the battery module and flows through the fluid outlet of the external container.

[0025] According to an embodiment of the present disclosure, a cooling panel for a battery system comprises a fluid, a fluid pump, a battery module having a plurality of battery cells, a first sheet having a first hole pattern, a second sheet having a second hole pattern, and at least one additional sheet having a third hole pattern, wherein the first sheet, the second sheet, and at least one additional sheet overlap to form a multilayer sheet, and the first sheet, the second sheet, and at least one additional sheet are made of a porous nonwoven material, and the first hole pattern of the first sheet, the second hole pattern of the second sheet, and the third hole pattern of the at least one additional sheet partially overlap to form a flow channel through the multilayer sheet, the multilayer sheet is disposed adjacent to the battery module, and the fluid pump moves the fluid through the flow channel of the multilayer sheet and the porous nonwoven material.

[0026] According to an additional embodiment, battery modules are contained within an external container having a fluid inlet and a fluid outlet.

[0027] According to an additional embodiment, the fluid pump moves fluid through the fluid inlet of the outer container, through the flow channel of the multilayer sheet, through the porous nonwoven material of the multilayer sheet, around the battery module, and through the fluid outlet of the outer container.

[0028] The present disclosure has a lightweight, efficient, multi-purpose multilayer sheet in which a safe and optimal environment for battery cells can be created. The present disclosure may have individual sheets having overlapping hole patterns, which help to spatialize battery cells in a battery module and form flow channels for a fluid to flow through the multilayer sheet. When a fluid moves through the multilayer sheet in contact with a battery cell or battery module, the fluid absorbs heat emitted from the battery cell or battery module.

[0029] The present disclosure of a multilayer sheet has manufacturing, system optimization, and assembly advantages. A multilayer sheet manufactured from individual sheets that overlap each other allows the manufacturing of the sheet to be simple and reproducible. The multilayer sheet can be optimized for system requirements by creating more complex hole patterns in the individual sheets that increase surface area and heat absorption and determine the fluid pressure drop across the system. These factors may be influenced by the complexity of the hole patterns affecting the flow channels through the multilayer sheet. The multilayer sheet is flexible and can be configured to contact a battery module on one side, or the multilayer sheet can be configured to surround each of the battery cells of the multilayer sheet to increase surface area and heat absorption. The multilayer sheet is lightweight and flexible, which reduces the need for tolerance lamination in vehicle assembly compared to rigid and heavy previous cooling panels. By using thin single layers, the total thickness of the array can be maintained at less than 0.5 mm, supporting space-saving battery designs.

[0030] Additional applicable areas will become apparent from the description provided herein. The descriptions and specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of this disclosure. Brief explanation of the drawing

[0031] The drawings described herein are merely for exemplary purposes of selected embodiments and are not intended to represent all possible embodiments, nor are they intended to limit the scope of the disclosure. FIG. 1 is a top view of exemplary individual sheets including a multilayer sheet. FIG. 1a is a top view of a multilayer sheet illustrating the overlap of individual sheets of FIG. 1 and the partial overlap of hole patterns of individual sheets. FIGS. 2, FIGS. 2a, and FIGS. 2b are top views of individual and separate sheets illustrating distinct hole patterns. FIG. 2c is a top view of a stacked pair of exemplary sheets having an alternative hole pattern. Figure 3 is a schematic diagram of a multilayer sheet in contact with a battery module. FIG. 4 is a schematic diagram of an immersion cooling fluid system of a vehicle having multilayer sheets surrounding battery modules. Corresponding reference numbers indicate corresponding parts across several drawings. Specific details for implementing the invention

[0032] Now, exemplary embodiments will be described more fully with reference to the accompanying drawings.

[0033] Exemplary embodiments are provided to ensure that the present disclosure is thorough and to fully convey the scope to those skilled in the art. To provide a thorough understanding of the embodiments of the present disclosure, many specific details, such as examples of specific components, devices, and methods, are presented. It will be apparent to those skilled in the art that specific details do not need to be adopted, that the exemplary embodiments may be implemented in many different forms, and that none of these should be construed as limiting the scope of the present disclosure. In some exemplary embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0034] The terms used herein are intended to describe specific exemplary embodiments only and are not intended to be limiting. As used herein, singular forms may be intended to include plural forms unless the context clearly indicates otherwise. The terms “include,” “comprising,” “comprising,” and “having” are inclusive and thus specify the presence of the mentioned features, integers, steps, actions, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, actions, elements, components, and / or groups thereof. The method steps, processes, and actions described herein should not be interpreted as requiring their execution in the specific order discussed or illustrated, unless specifically identified as such. It should also be understood that additional or alternative steps may be employed.

[0035] When an element or layer is referred to as being "on," "engaged to," "connected to," or "joined to" another element or layer, it may be directly on the other element or layer, engaged to, connected to, or joined thereto, or interposed elements or layers may exist. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly joined to" another element or layer, interposed elements or layers may not exist. Other words used to describe relationships between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated enumerated items.

[0036] Although terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms as used herein do not imply a sequence or order unless clearly indicated by the context. Accordingly, the first element, component, region, layer, or section discussed below may be referred to as the second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0037] Spatially relative terms such as "inside," "outside," "bottom," "below," "lower," "top," "upper," and others may be used herein for ease of description to explain the relationship between one element or feature and another element(s) or feature(s), as exemplified in the drawings. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the drawings. For example, if the device in the drawings is inverted, elements described as "below" or "bottom" of other elements or features will be oriented "above" of other elements or features. Accordingly, the exemplary term "below" may encompass both the up and down orientations. The device may be oriented in other ways (rotated 90 degrees or other orientations), and the spatially relative descriptors used herein may be interpreted accordingly.

[0038] Referring to FIG. 1, a multilayer sheet (10) according to the principles of the present disclosure is illustrated. The multilayer sheet (10) can serve as a cooling panel for an electric vehicle that facilitates a safe and optimal environment for battery operations. The multilayer sheet (10) may include a first sheet (12), a second sheet (14), an additional or third sheet (16), and a flow channel (18). The first sheet (12), the second sheet (14), and the additional sheet (16) may be folded along fold lines (19) so as to overlap each other, and each sheet includes a different hole pattern (22a, 22b, 22c) that is different from the other sheets or is the same as the other sheets and offset with respect to the dimensions of the sheets. The hole patterns (22a, 22b, 22c) partially overlap to form a flow channel (18). A fluid (20), which may be engine coolant / antifreeze, water, or other heat-absorbing fluid, is moved or flows through a flow channel (18) formed by the partial overlap of hole patterns (22a, 22b, 22c, 22d). Potential hole patterns of the sheets are illustrated in FIG. 2, FIG. 2a, FIG. 2b, and FIG. 2c. The hole patterns may be different shapes and combinations of shapes. The holes may be elongated, curved, zigzag, rectangular, circular, trapezoidal, hexagonal, and other shapes that partially overlap with holes in other sheets.

[0039] FIG. 2c illustrates a pair of stacked sheets (112, 114) having hexagonal holes (22d, 22e) that are offset from each other and overlap at the tip ends to provide a flow path through holes (22d, 22e) that overlap in a serpentine pattern as a coolant fluid flows along the length of the stacked sheets (112, 114).

[0040] The sheets of FIGS. 2, FIGS. 2a, FIGS. 2b, and FIGS. 2c are made of a nonwoven material or other material that can maintain the structure and allow hole patterns to be formed. Alternative materials may include, but are not limited to, plastic sheets, carbon fiber mats, rubber sheets, foam sheets, and metal sheets. The hole patterns may be laser-cut or stamp-cut as individual roles of the sheets, and the sheets may be overlaid on top of each other. Forming the first sheet (12), the second sheet (14), and the additional sheet (16) from three separate sheets reduces manufacturing time and allows for complexity of the hole patterns. The complexity of the flow channel (18) is directly related to the complexity of the hole patterns (22a-22d) of each sheet. Desired pressure drop and turbulence of the fluid (20) can be formed by modifying or making the hole patterns more complex, which will make the flow channel (18) more complex through the multilayer sheet (10). This allows the system requirements and the heat absorption of the fluid (20) to be configured for different electric vehicle system requirements. It is considered that hole patterns can be removed from a single material sheet that can be folded along fold lines (19) to separate a single sheet into a multilayer sheet with different panels folded over each other. Forming hole patterns (22a-22d) from a single sheet reduces the potential for misalignment during the overlap of the hole patterns (22a-22d). It is also considered that the multilayer sheet (10) can form a number of flow channels (18). The sheets are preferably combined to have a thickness of 50 microns to 2000 microns.

[0041] As illustrated in FIG. 3, a battery system (24) comprising a housing (42) and a plurality of battery modules or cells (26) arranged together with the housing (42) is illustrated. A cooling plate (40) supports the battery modules or cells (26), and a multilayer sheet (10) is in contact with the battery modules or cells (26) and the cooling plate (40). The cooling plate (40) may include a fluid inlet (44) and a fluid outlet (46) for moving a fluid (20) through the cooling plate (40). The multilayer sheet (10) may be made of a thermally conductive material such as graphite. Flow channels (18) allow a gaseous or liquid coolant to flow through the multilayer sheet (10) to dissipate heat therefrom. The multilayer sheet (10) can conform to the bottom of the battery modules or cells (26) and can provide improved heat transfer from the battery modules or cells to the cooling plate (40). The cooling plate can be placed under the prismatic cells or between the prismatic cells. It can also be placed between pouch cells or between round cells.

[0042] Referring to FIG. 4, the battery system comprises a plurality of battery modules or cells (26) disposed in a battery housing (50) that includes a fluid system (52) which may include a cooling device (54), a fluid reservoir (56), a pump (58), and a temperature control unit (60). Multilayer sheets (10) are disposed below and between the battery modules / cells (26). Fluid movement within the housing (50) is facilitated by a series of tubes and connectors (62) throughout the system connecting each fluid system (28) component. Cooling fluid (64) is moved from the battery housing (50), the cooling device (54), and the reservoir (56) to the temperature control unit (60) by the fluid pump (58). The temperature control unit (60) controls the temperature of the fluid (64) to an optimal temperature for the operation of the battery modules / cells (26). The fluid (64) flows through the fluid inlet (66) of the battery housing (50) into the flow channels (18) of the multilayer sheet (10). The cooling fluid (64) absorbs heat from the battery modules / cells (26) while flowing through the flow channels (18) of the multilayer sheet (10) inside the battery housing (50). From the flow channels (18) of the multilayer sheets (10), the fluid (20) moves through the fluid outlet (68) of the battery housing (50).

[0043] The multilayer sheet (10) may be configured to be under the battery modules / cells (26) as shown in FIG. 3, or to surround each battery module (26) as shown in FIG. 4, which is considered to increase the surface area for heat exchange of the fluid (64). In both configurations, sensors (70) throughout the fluid system (28) can determine and control the flow and temperature of the fluid (64) inside the fluid system (52) and detect conductivity to form a safe and optimal environment for the operation of multiple battery cells (26).

[0044] The cooling panel of the present disclosure can be used with other electronic devices requiring cooling to provide improved fluid circulation around the electronic device.

[0045] The foregoing description of the embodiments is provided for illustrative and illustrative purposes only. It is not intended to encompass or limit the entirety of the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment but may be used in selected embodiments where applicable, interchangeably, and even if not specifically illustrated or described. This may also be modified in various ways. Such modifications should not be construed as departing from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

Claim 1 A cooling panel for an electronic system requiring cooling, comprising: a first sheet having a first hole pattern; and a second sheet having a second hole pattern that is different from or offset from the first hole pattern; wherein the first sheet and the second sheet overlap to form a multilayer sheet, and the first hole pattern of the first sheet and the second hole pattern of the second sheet partially overlap to form a flow channel along the length of the multilayer sheet. Claim 2 A cooling panel according to claim 1, further comprising at least one additional sheet having a third hole pattern different from the second hole pattern, wherein the at least one additional sheet overlaps the first sheet and the second sheet. Claim 3 In paragraph 2, the first sheet, the second sheet, and the at least one additional sheet have a thickness of 50 microns to 2000 microns, forming a cooling panel. Claim 4 In paragraph 1, the multilayer sheet is a cooling panel disposed in a battery system. Claim 5 A cooling panel in which fluid flows through the above-mentioned flow channel, wherein, in claim 1. Claim 6 A cooling panel according to claim 1, wherein the first sheet and the second sheet are made of any one of plastic, carbon, graphite, metal, fibrous fabric, foam, and nonwoven material. Claim 7 In claim 6, the first hole pattern of the first sheet, the second hole pattern of the second sheet, and the third hole pattern of the at least one additional sheet are formed by removing material from the nonwoven material, forming a cooling panel. Claim 8 In paragraph 1, the multilayer sheet is a cooling panel disposed inside a cooler. Claim 9 A battery system comprising: a battery module having a plurality of battery cells; a first sheet having a first hole pattern; and a second sheet having a second hole pattern that is different from or offset from the first hole pattern; wherein the first sheet and the second sheet overlap to form a multilayer sheet, and the first hole pattern of the first sheet and the second hole pattern of the second sheet partially overlap to form a flow channel through the multilayer sheet, and the multilayer sheet contacts the battery module directly or through a cooler. Claim 10 A battery system according to claim 9, wherein the first sheet and the second sheet have a thickness of 50 microns to 2000 microns. Claim 11 A battery system according to claim 9, wherein the first sheet and the second sheet are made of any one of plastic, carbon, graphite, metal, fibrous fabric, foam, and nonwoven material. Claim 12 In claim 9, the battery system has a housing that encapsulates the plurality of battery cells. Claim 13 In paragraph 12, the above housing is a battery system having a fluid inlet and a fluid outlet. Claim 14 A battery system in which, in paragraph 13, a fluid flows to a fluid outlet through the fluid inlet of the housing and the flow channel of the multilayer sheet. Claim 15 A battery system according to claim 9, further comprising at least one additional sheet having a third hole pattern different from the second hole pattern, wherein the at least one additional sheet overlaps the first sheet and the second sheet. Claim 16 In claim 9, the battery system wherein the multilayer sheet is disposed below or between the plurality of battery cells. Claim 17 In claim 9, the battery system wherein the plurality of battery cells is one of a prismatic pouch of circular cells contacted by the multilayer sheet. Claim 18 A battery system comprising: a fluid; a fluid pump; a battery housing having a plurality of battery modules; a first sheet having a first hole pattern; a second sheet having a second hole pattern; and at least one additional sheet having a third hole pattern, wherein the first sheet, the second sheet, and the third sheet overlap to form a multilayer sheet, and the first sheet, the second sheet, and the third sheet are made of a porous nonwoven material, and the first hole pattern of the first sheet, the second hole pattern of the second sheet, and the third hole pattern of the at least one additional sheet partially overlap to form a flow channel through the multilayer sheet, and the multilayer sheet is disposed in contact with a portion of the plurality of battery modules, and the fluid pump moves the fluid through the flow channel of the multilayer sheet and the porous nonwoven material. Claim 19 In paragraph 18, the battery housing is a cooling panel having a fluid inlet and a fluid outlet. Claim 20 In claim 19, the fluid pump moves the fluid through the fluid inlet of the battery housing, through the flow channel of the multilayer sheet, through the porous nonwoven material of the multilayer sheet, around the plurality of battery modules, and through the fluid outlet of the housing, a cooling panel.

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