Battery module with coolant flow control

Patent metadata

Field	Value
Publication number	US-2025233224-A1
Application number	US-202418409864-A
Country	US
Kind code	A1
Filing date	Jan 11, 2024
Priority date	Jan 11, 2024
Publication date	Jul 17, 2025
Grant date	—

Abstract

A battery module including a plurality of battery cells configured for storing and supplying electrical power, a cell holder configured for supporting the battery cells, a preformed insert including a potting material shaped to define a plurality of coolant channels for the battery cells, and a flow control system operable for controlling a coolant flow through the coolant channels.

First claim

What is claimed is:

1 . A battery module, comprising:
a plurality of battery cells configured for storing and supplying electrical power; a cell holder configured for supporting the battery cells; a preformed insert disposed relative to the cell holder and the battery cells, the preformed insert including a potting material shaped to define a plurality of coolant channels for the battery cells; and a flow control system operable for controlling a coolant flow through the coolant channels.

2 . The battery module according to claim 1 , wherein
the flow control system includes a plurality of flow diverters disposed within the potting material, wherein the flow diverters are configured for metering the coolant flow through a respective one of the coolant channels.

3 . The battery module according to claim 2 , wherein
the flow diverters are configured for contracting from a nominal state to a smaller state in response to a coolant temperature of the coolant flow thereat surpassing a nominal temperature threshold.

4 . The battery module according to claim 3 , wherein
the flow diverters are configured for contracting to a minimal state smaller than the nominal state in response to a coolant temperature thereat surpassing the nominal temperature threshold by a predefined amount.

5 . The battery module according to claim 4 , wherein
the nominal state results in the flow diverters obstructing a greater portion of the coolant channels than when in the minimal state such that the nominal state restricts the coolant flow more than the minimal state.

6 . The battery module according to claim 1 , wherein:
the preformed insert includes a plurality of cell cavities fluidly interconnected with the coolant channels, wherein the cell cavities are shaped within the potting material to receive a respective one of the battery cells.

7 . The battery module according to claim 6 , wherein
the coolant channels are formed with a spiral shape around the cell cavities, wherein the spiral shape directs the coolant flow in a circular manner from top to bottom or from bottom to top of a respective one of the cell cavities.

8 . The battery module according to claim 1 , wherein
the flow control system includes a coolant container configured for enclosing the preformed insert and the battery cells within a sealed enclosure, wherein the sealed enclosure is operable for directing the coolant flow through the coolant channels and around the battery cells to provide immersive cooling.

9 . The battery module according to claim 8 , wherein
the coolant container includes a pressure release valve configured for releasing the coolant flow to an exterior of the sealed enclosure in response to a pressure within the sealed enclosure surpassing a pressure threshold.

10 . The battery module according to claim 1 , wherein:
the preformed insert includes a plurality of thermal channels for the battery cells, wherein the thermal channels are configured for retaining a thermal fluid separately from the coolant flow when a coolant temperature of the coolant flow is less than a thermal threshold and for releasing the thermal fluid into the coolant flow when the coolant temperature surpasses the thermal threshold.

11 . The battery module according to claim 1 , wherein:
the flow control system includes a flow manifold operable for directing a coolant input having a coolant to the coolant channels to produce the coolant flow therethrough.

12 . The battery module according to claim 11 , wherein:
the flow control system includes an input and an output for each respective one of the coolant channels and a flow director operable for selectively metering the coolant through the inputs and outputs, and thereby, the coolant flow through the respective coolant channel.

13 . The battery module according to claim 12 , wherein:
the flow control system includes a plurality of temperature sensors disposed relative to the battery cells and/or the coolant channels; and the flow director is operable for metering the coolant based on temperatures measured with the temperature sensors.

14 . A battery module, comprising:
a plurality of battery cells configured for storing and supplying electrical power; a preformed insert including a potting material shaped to define a plurality of cell cavities and a plurality of cooling channels, wherein the cell cavities are configured for retaining the battery cells and the cooling channels are configured for directing a coolant flow relative to the cell cavities; a coolant container configured for enclosing the preformed insert and the battery cells within a sealed enclosure; and a flow control system operable for cycling a coolant through the coolant channels and the coolant container to immersively cool the battery cells.

15 . The battery module according to claim 14 , wherein
the immersive flow control system includes a plurality of flow diverters disposed within the coolant channels, wherein the flow diverters are configured for expanding and contracting based on a coolant temperature of the coolant flow thereat.

16 . The battery module according to claim 15 , wherein:
the flow diverters are configured for contracting from a nominal state to a minimal state in response to a coolant temperature thereat surpassing a nominal temperature threshold by a predefined amount, wherein the nominal state results in the flow diverters obstructing a greater portion of the coolant channels than when in the minimal state.

17 . The battery module according to claim 14 , wherein
the coolant channels are formed with a spiral shape that directs the coolant flow in a circular manner from top to bottom or from bottom to top of a respective one of the cell cavities.

18 . A vehicle, comprising:
an electric motor configured for converting electrical power to mechanical power suitable for use in propelling the vehicle; and a rechargeable energy storage system (RESS) having one or more energy modules configured for storing and supplying the electrical power, wherein the energy modules respectively include:
a plurality of energy cells configured for storing and supplying electrical power;
a preformed insert including a potting material shaped to define a plurality of cell cavities and a plurality of cooling channels, wherein the cell cavities are configured for receiving the energy cells and the cooling channels are configured for directing a coolant flow relative to the cell cavities;
a coolant container configured for enclosing the preformed insert and the energy cells within a sealed enclosure; and
an immersive flow control system operable for cycling a coolant through the coolant channels and the coolant container to immersively cool the energy cells.

19 . The vehicle according to claim 18 , wherein:
the energy modules each include a busbar configured for electrically interconnecting the energy cells thereof, wherein the busbars respectively connect to a portion of the energy cells above the preformed insert and within the coolant container such that the busbars are immersively cooled.

20 . The vehicle according to claim 19 , wherein:
the immersive flow control system includes a plurality of flow diverters disposed within the coolant channels, wherein the flow diverters are configured for expanding and contracting based on a coolant temperature of the coolant flow thereat such that the flow diverters contract from a nominal state to a minimal state in response to a coolant temperatur

Assignees

• Gm Global Tech Operations Llc

Inventors

• Patil Chinmaya
• Spicer John P
• Saez Miguel Arturo
• Raghavan Madhusudan
• Cogan Christopher D
• Wahl Ronald
• Jadike Jeff

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M10/6567

  Liquids · CPC title

• H01M10/6557

  arranged between the cells · CPC title

• H01M10/625

  Vehicles · CPC title

• H01M10/6556

  Solid parts with flow channel passages or pipes for heat exchange (closed pipes H01M10/6552) · CPC title