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JP-7855072-B2 - Cooling system for battery structures in single-bay and multi-bay electric vehicles

JP7855072B2JP 7855072 B2JP7855072 B2JP 7855072B2JP-7855072-B2

Inventors

  • カールソン，ダニエル
  • ウォールボリ，マルティン ヒェルム
  • ペルソン，クラス

Assignees

  • ボルボ・カー・コーポレーション

Dates

Publication Date
20260507
Application Date
20221123
Priority Date
20211126

Claims (17)

  1. A battery pack (4) used in an electric vehicle, wherein the battery pack (4) is It is interconnected by two spaced sill members (6, 7) extending in the length direction (L) , and each of them has a lateral front part (8) and lateral members (9, 15) extending in the width direction (W) , At least two rectangular battery cells (63, 64, 65) are arranged in an array (13, 14) having horizontal rows (25, 26, 27, 28) and longitudinal sides (33, 34), and extending adjacently in the longitudinal direction (L), forming longitudinal rows (16, 17, 18, 19), Interposed between adjacent cells (63, 64, 65) in the longitudinal rows (16, 17, 18, 19), cooling plates (21, 22, 23) extending in the width direction (W) from the first longitudinal side (33) to the second longitudinal side (34) of the array (13, 14), The sill members (6, 7) include a coolant distribution duct (30) and a coolant discharge duct (30') extending parallel to each other, Each of the cooling plates (21, 22, 23) is connected to an inlet leading to the coolant distribution duct (30) and an outlet leading to the coolant discharge duct (30'), The coolant distribution duct (30) is connected to the coolant supply duct (31), and the coolant discharge duct (30') is connected to the coolant return duct (31'). The coolant supply duct ( 31 ) and the coolant return duct (31') pass through the front component (8) and/or the lateral members (9, 15), The distribution cooling member (32) is provided with an end having mounting portions (57, 58) that extend substantially parallel to the cooling plates (41, 42), a cover that is liquid-tightly engaged with the mounting portions (57, 58) to form a receiving chamber (66), and a connector stub (43) supported by the cover for connecting the coolant distribution duct (30) to the coolant supply duct (31). Battery pack (4).
  2. The battery pack (4) according to claim 1, The cooling plates (21, 22, 23) are provided between each adjacent pair of cells in the row of the horizontal cells (25, 26, 27, 28). Battery pack (4).
  3. The battery pack (4) according to claim 1, The cooling plates (21, 22, 23) are provided every other pair between adjacent pairs of adjacent horizontal cells (25, 26, 27, 28) in a row. Battery pack (4).
  4. A battery pack (4) according to any one of claims 1 to 3, The front part (8) and the lateral member (15) apply a compressive force of 20 to 200 kN/ m² to the cell in the longitudinal direction. Battery pack (4).
  5. A battery pack (4) according to any one of claims 1 to 3, The coolant supply duct (31) is connected to the midpoint or vicinity of the coolant distribution duct (30). Battery pack (4).
  6. A battery pack (4) according to any one of claims 1 to 3, The cooling plates (21', 23') are provided between the lateral front component (8) and the adjacent row of lateral cells (25'), and between the lateral member (15) and the adjacent row of lateral cells (28'). Battery pack (4).
  7. A battery pack (4) according to any one of claims 1 to 3, The distance (d) between the longitudinal sides (33, 34) of the array (13, 14) and the sill members (6, 7) in the width direction (W) is between 5 cm and 25 cm. The coolant supply duct (31) and the coolant return duct (31') extend between the longitudinal sides (33, 34) of the array and the sill members (6, 7). Battery pack (4).
  8. A battery pack (4) according to any one of claims 1 to 3, The lateral member (15) includes a beam or foot garage and the lateral rear part (9) that connects the rear parts of the sill members (6, 7) to each other. The first array of cells (13) is located between the lateral front component (8) and the beam or the foot garage. The second array of cells (14) is located between the beam or the foot garage and the lateral rear component (9), Each of the arrays (13, 14) of the cell is provided with the cooling plates (21, 22, 23), the coolant inlet and distribution ducts (30, 31), and the coolant discharge duct and the coolant return ducts (30', 31'). The coolant supply ducts and coolant return ducts (31, 31') of the first array (13) and second array (14) of the cell penetrate the lateral front component (8) and the beam or the foot garage. Battery pack (4).
  9. A battery pack (4) according to any one of claims 1 to 3, Each of the cooling plates (21, 22, 23) includes two parallel cooling plates (41, 42) having end caps (40, 50) with two lateral tubular portions (44, 45; 51, 52), The tube portions (44, 45, 51, 52) are interconnected to form the coolant distribution duct (30). Battery pack (4).
  10. The battery pack (4) according to claim 9, The lateral tubular portions (51, 53) of adjacent cooling plates (48, 54) are each connected to one another via an elastic tubular member (55). Battery pack (4).
  11. The battery pack (4) according to claim 9, The support structure (68) is positioned between the two parallel cooling plates (41, 42) of at least one of the cooling plates (21, 22, 23). Battery pack (4).
  12. Cooling members (48, 49, 54) for the battery pack (4), Two parallel cooling plates (41, 42) and The cooling plates (41, 42) are arranged substantially parallel to each other, Two end caps (50) are connected in a liquid-tight manner to the cooling plates (41, 42) and along the outer circumference in a liquid-tight manner, The cooling plates (41, 42) extend laterally to the respective sides of the end cap (50), In order to form a coolant distribution duct (30) together with adjacent cooling members, tube portions (51, 52) are configured to be connected to adjacent tube portions (44, 53), Two end caps (40) are liquid-tightly connected to the cooling plate, A connector stub (43) for connecting to the coolant supply duct (31), Includes , At least one of the end caps (40) has mounting portions (57, 58) that extend substantially parallel to the cooling plates (41, 42), and a cover that is liquid-tightly engaged with the mounting portions (57, 58) to form a receiving chamber (66), The connector stub (43) is supported by the cover and connects the coolant distribution duct (30) to the coolant supply duct (31). Cooling components (48, 49, 54).
  13. Cooling members (48, 49, 54) for the battery pack (4), Two parallel cooling plates (41, 42) and Two end caps (40) are liquid-tightly connected to the cooling plate, A connector stub (43) for connecting to the coolant supply duct (31), Equipped with, At least one end cap (40) has mounting portions (57, 58) that extend substantially parallel to the cooling plates (41, 42), and a cover that is liquid-tightly engaged with the mounting portions (57, 58) to form a receiving chamber (66), The connector stub (43) is supported by the cover and connects the coolant distribution duct (30) to the coolant supply duct (31). Cooling components (48, 49, 54).
  14. A cooling system for a battery pack (4), A cooling member comprising at least one cooling member according to claim 12 and/or at least one cooling member according to claim 13, Cooling system.
  15. Includes a battery pack (4) according to any one of claims 1 to 3, Electric vehicles.
  16. A method for manufacturing a battery pack (4) for an electric vehicle, An array (13, 14) of at least two rows (16, 17, 18, 19) of rectangular battery cells (63, 64, 65) having longitudinal sides (33, 34) and extending adjacent to each other in the longitudinal direction (L), The steps include forming cooling plates (21, 22, 23) arranged in horizontal rows (25, 26, 27, 28) and positioned between adjacent cells, extending in the width direction (W) from the longitudinal upstream edge (33) to the longitudinal opposite edge (34) of the array (13, 14), In order to compress the array (13, 14), the steps include: firmly fixing the array (13, 14) between a lateral front component (8) extending in the width direction (W) and lateral members (9, 15); The steps include connecting the aforementioned lateral front part (8) and the aforementioned lateral members (9, 15) to each other via two sill members (6, 7) that extend along their respective longitudinal sides (33, 34), The cooling plates (21, 22, 23) are connected to the coolant supply duct (31) and the coolant return duct (31') by passing through the lateral front component (8) and/or the lateral members (9, 15), wherein the cooling plates (21, 22, 23) are The two parallel cooling plates (41, 42) and Two end caps (40) are liquid-tightly connected to the cooling plate, A connector stub (43) for connecting to the coolant supply duct (31), Equipped with, At least one end cap (40) has mounting portions (57, 58) that extend substantially parallel to the cooling plates (41, 42), and a cover that is liquid-tightly engaged with the mounting portions (57, 58) to form a receiving chamber (66), The connector stub (43) is supported by the cover and connects the coolant distribution duct (30) to the coolant supply duct (31). Manufacturing method.
  17. A manufacturing method according to claim 16 , Before the sill members (6, 7) are connected, the cooling plates (21, 22, 23) are connected to each other via the elastic duct portion (55). Manufacturing method.

Description

This invention relates to a battery pack used in electric vehicles. The battery pack is interconnected by two spaced sill members extending in the longitudinal direction, each including a lateral front component and a lateral component extending in the width direction. At least two longitudinal rows of rectangular battery cells extend adjacently in the longitudinal direction. The present invention also relates to a cooling element used in such a battery pack and a method for manufacturing the same. Battery electric vehicles (BEVs) and their powertrains are typically powered by an array of batteries connected in series, parallel, or a combination of both, to reach the desired system output voltage window that optimizes the efficiency of the motor and drivetrain. Battery cells come in various shapes, such as cylindrical, prismatic, and pouch-type, and generate heat due to internal resistance when power is consumed (acceleration) or applied (charging). This generated heat is actively removed to prevent the cell temperature from exceeding a set threshold. At this threshold temperature, the cell's electrolyte is destroyed, causing permanent damage to the cell and substantially reducing its lifespan. Therefore, one of the critical design parameters for battery packs in electric vehicles is to keep the absolute temperature below a certain limit to ensure sufficient cell life and product safety. However, depending on the internal structure of the cell and the manufacturing method (wound or laminated jelly roll), heat may not be evenly distributed in all directions of the cell, resulting in a temperature gradient with substantially hot and cold regions. It is desirable to reduce the temperature gradient as much as possible and achieve a very uniform temperature distribution throughout the cell with reduced differences between hot and cold areas. To protect the electrolyte within the battery cell from damage, when the cell temperature exceeds a set value, power input and output are typically limited (suppressed) while hotter areas of the cell simultaneously occur. Therefore, if a region of the cell overheats, the control hardware and software begin to suppress the protocol to protect the electrolyte. This problem is most frequently experienced by consumers when fast charging at high voltage and high current. Typical fast charging takes 10 to 30 minutes, depending on the type of vehicle and the output rating of the charging station. In contrast to the long charging time during power input, power output from the cell during acceleration or overtaking on an approach is a relatively short event, usually less than a minute, but can be repeated several times in shorter intervals. To provide a better fast-charging experience (shorter charging time), the battery pack needs to have cells with an optimized internal structure and a powerful cooling system to avoid the occurrence of high-temperature areas. Battery packs are known to have cylindrical battery cells that are cooled by a series of meandering cooling plates that extend longitudinally. As a result, known cooling plates can exhibit uneven cooling along their length, potentially creating localized high-temperature areas. An object of the present invention is to provide a battery pack with an effective cooling system having a substantially uniform temperature distribution when power is supplied by the battery cells and when the cells are being charged. A further object of the present invention is to provide an electric vehicle equipped with a structural battery that is relatively lightweight and rechargeable in relatively fast charging cycles. The battery pack is used for use in electric vehicles. The battery pack includes a lateral front component and lateral members, each connected to the others by two spaced sill members, each extending in width and length. At least two longitudinal rows of prismatic battery cells extend adjacently in the length direction. The cells are tiled in an array, including the lateral rows. The array has longitudinal sides. The battery pack further includes plate-shaped cooling members interposed between adjacent cells in the longitudinal rows, extending in width from a first longitudinal side to a second longitudinal side of the array. Each plate-shaped cooling member is connected to an inlet leading to a coolant distribution duct and an outlet leading to a coolant discharge duct. The distribution and discharge ducts extend parallel to the sill members. The distribution ducts are connected to the coolant supply ducts, and the discharge ducts are connected to the return ducts. The coolant supply duct and return duct penetrate the front component and/or lateral members. In this configuration, at least two longitudinal rows extend in the length direction. Furthermore, at least two longitudinal rows are arranged adjacent to each other. That is, at least two longitudinal rows are arranged adjacent to each other in the width direction. Within one