Battery module for vehicle energy-storage systems

Patent metadata

Field	Value
Publication number	US-2017005384-A1
Application number	US-201514946699-A
Country	US
Kind code	A1
Filing date	Nov 19, 2015
Priority date	Jun 30, 2015
Publication date	Jan 5, 2017
Grant date	—

Abstract

Provided are battery modules. Each module may comprise an enclosure having a base, the base having a plurality of first holes disposed therein, the enclosure including a coolant input port, a coolant output port; the enclosure having a coolant sub-system for circulating coolant being directed into the enclosure through the coolant input port and the plurality of first holes and out of the enclosure through the coolant output port; a center divider affixed to the enclosure; a module cover coupled to the enclosure at an opposite end of the module from the center divider; a retainer disposed within the enclosure and configured to support a plurality of cells; a current carrier disposed between the module cover and the retainer; and the plurality of cells disposed between the current carrier and the center divider, the cells being coupled to and supported by the retainer.

First claim

What is claimed is:

1 . A battery module comprising:
an enclosure having a base, the base having a plurality of first holes disposed therein, the enclosure including a coolant input port and a coolant output port; the enclosure having a coolant sub-system for circulating coolant being directed into the enclosure through the coolant input port and the plurality of first holes and out of the enclosure through the coolant output port; a center divider affixed to the enclosure;
a module cover coupled to the enclosure at an opposite end of the module from the center divider;
a retainer disposed within the enclosure and configured to support a plurality of cells; a current carrier disposed between the module cover and the retainer; and the plurality of cells disposed between the current carrier and the center divider, the cells being coupled to and supported by the retainer.

2 . The battery module of claim 1 , wherein the plurality of first holes each have a diameter in a range from 0.1 mm-5 mm.

3 . The battery module of claim 2 , wherein the plurality of first holes are disposed on the base such that each first hole of the plurality of first holes receives substantially the same inlet pressure and approximately the same volume flow is maintained through each first hole.

4 . The battery module of claim 3 , wherein the substantially same inlet pressure is in a range of 0.05 psi-5 psi and the approximately same volume flow is 0.05 L/min-5 L/min.

5 . The battery module of claim 1 , wherein the module cover, the enclosure, and the center divider are each comprised of at least one of: polycarbonate, polypropylene, acrylic, nylon, and acrylonitrile butadiene styrene (ABS), and the module cover and the center divider are each affixed to the enclosure, forming a hermetic seal.

6 . The battery module of claim 1 , wherein the module cover and center divider comprise laser-transmissive polycarbonate, the enclosure comprises laser-absorptive polycarbonate, and the module cover and the center divider are each affixed to the enclosure, forming a hermetic seal.

7 . The battery module of claim 1 further comprising:
a tray having the plurality of modules disposed therein, the tray including:
a positive bus bar;
a negative bus bar, the positive and negative bus bars being separately electrically coupled to the power connectors associated with the plurality of modules; and
a plurality of lateral supports; and

a coolant system for circulating coolant being pumped into the tray such that each of the modules is at approximately the same predetermined temperature.

8 . The battery module of claim 1 , wherein the retainer includes a plurality of second holes configured to direct the coolant from the base of the enclosure to the current carrier.

9 . The battery module of claim 8 , wherein the current carrier includes a plurality of third holes configured to direct the coolant outside of the enclosure.

10 . The battery module of claim 9 , wherein the plurality of second holes and the plurality of third holes are substantially aligned.

11 . The battery module of claim 1 , wherein the current carrier is coupled to the retainer through a plurality of stubs formed on the retainer.

12 . A battery comprising a plurality of the battery modules of claim 1 , wherein at least some of the plurality of battery modules are fluidically coupled in series.

13 . An energy-storage system for a vehicle comprising:
a plurality of modules fluidly communicating with each other, each module including:
an enclosure including a base, the base having a plurality of holes disposed therein, the enclosure including a coolant input port, a coolant output port, and a power connector; the enclosure having a coolant sub-system for circulating coolant being directed into the enclosure through the coolant input port and the plurality of holes and out of the enclosure through the coolant output port;
a blast plate coupled to the base of the enclosure;
a module cover disposed at an opposite end of the module from the blast plate;
a retainer disposed within the enclosure and configured to support a plurality of cells;
a current carrier disposed between the module cover and the retainer and electrically coupled to the power connector; and
the plurality of cells disposed in the enclosure and secured by the retainer and the base, electrical connections being formed between the plurality of cells and the current carrier.

14 . The energy storage system of claim 13 , wherein the plurality of holes each have a diameter in a range from 0.1 mm-5 mm.

15 . The energy storage system of claim 14 , wherein the plurality of holes are disposed on the base such that each hole of the plurality of holes receives substantially the same inlet pressure and approximately the same volume flow is maintained through each hole.

16 . The energy storage system of claim 15 , wherein the substantially same inlet pressure is in a range of 0.05 psi-5 psi and the approximately same volume flow is 0.05 L/min-5 L/min.

17 . The energy storage system of claim 13 , wherein the module cover, the enclosure, and the blast plate are each comprised of at least one: of polycarbonate, polypropylene, acrylic, nylon, and acrylonitrile butadiene styrene (ABS), and the module cover and the blast plate are each affixed to the enclosure, forming a hermetic seal.

18 . The energy-storage system of claim 13 , wherein the module cover and blast plate comprise laser-transmissive polycarbonate, the enclosure comprises laser-absorptive polycarbonate, and the module cover and the blast plate are each affixed to the enclosure using at least laser welding, forming a hermetic seal.

19 . The energy-storage system of claim 13 further comprising:
a tray having the plurality of modules disposed therein, the tray including:
a positive bus bar;
a negative bus bar, the positive and negative bus bars being separately electrically coupled to the power connectors associated with the plurality of modules; and
a plurality of lateral supports; and
a coolant system for circulating coolant being pumped into the tray such that each of the modules is at approximately the same predetermined temperature,

wherein the enclosure further includes a first tab disposed at a first end of the enclosure and a second tab disposed at a second end of the enclosure, the first end being distal from the second end, and the first tab and the second tab being mechanically coupled to a respective lateral support of the plurality of lateral supports.

20 . An energy-storage module for a vehicle comprising:
a housing enclosing a first group of battery cells and a second group of battery cells, the housing including a coolant inlet port configured to receive coolant and a coolant outlet port configured to release coolant; and a cooling system formed within the housing between the coolant inlet port and the coolant outlet port, the cooling system is configured to separate the coolant into a first coolant flow directed to the first group of battery cells and a second coolant flow directed to the second group of battery cells, wherein the first coolant flow flows over the first group of battery cells in a first direction and the second coolant flow flows over the second group of battery cells in a second direction, and wherein the first direction and the second direction are opposite to each other.

Assignees

• Faraday&Future Inc

Inventors

• Harris W Porter
• Rosengren Blake
• Sampson Nicholas John

Classifications

• H01M10/656

  characterised by the type of heat-exchange fluid · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title

• H01M10/6557 Primary

  arranged between the cells · CPC title

• H01M10/613

  Cooling or keeping cold · CPC title

• H01M10/625

  Vehicles · CPC title