Abstract:
A battery cooling and retainer assembly according to an exemplary aspect of the present disclosure includes, among other things, a first retainer section that includes a first retention feature, a second retainer section that includes a second retention feature, and a cooling channel disposed between the first retainer section and the second retainer section.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to an electrified vehicle, and more particularly, but not exclusively, to a battery cooling channel having integrated cell retention features for simultaneously cooling and retaining the battery cells of a battery module. 
       BACKGROUND 
       [0002]    Electrified vehicles such as hybrid electric vehicles (HEV&#39;s), plug-in hybrid electric vehicles (PHEV&#39;s), battery electric vehicles (BEV&#39;s), or fuel cell vehicles differ from conventional engine vehicles in that they are powered by one or more electric machines (i.e., electric motors and/or generators) instead of or in addition to an internal combustion engine. High voltage current for powering electric machines is typically supplied by a high voltage traction battery pack that stores energy. 
         [0003]    Electrified vehicle battery packs are made up of multiple battery modules. The battery cells of such battery modules may need thermally managed to remove excess heat out of the battery pack. Some battery pack designs may additionally require securely retaining the battery cells relative to one another to achieve a proper electrical connection. 
       SUMMARY 
       [0004]    A battery cooling and retainer assembly according to an exemplary aspect of the present disclosure includes, among other things, a first retainer section that includes a first retention feature, a second retainer section that includes a second retention feature, and a cooling channel disposed between the first retainer section and the second retainer section. 
         [0005]    In a further non-limiting embodiment of the foregoing assembly, the first retainer section is disposed on a first side of a cooling housing and the second retainer section is disposed on a second, opposite side of the cooling housing. 
         [0006]    In a further non-limiting embodiment of either of the foregoing assemblies, the cooling channel extends inside of the cooling housing. 
         [0007]    In a further non-limiting embodiment of any of the foregoing assemblies, the first retention feature and the second retention feature include spaced apart arms that circumscribe a pocket. 
         [0008]    In a further non-limiting embodiment of any of the foregoing assemblies, a shelf extends between the spaced apart arms. 
         [0009]    In a further non-limiting embodiment of any of the foregoing assemblies, the pocket in semi-cylindrical shaped. 
         [0010]    In a further non-limiting embodiment of any of the foregoing assemblies, the spaced apart arms are flexible between a collapsed position and a flexed position. 
         [0011]    In a further non-limiting embodiment of any of the foregoing assemblies, the first retainer section and the second retainer section include a plurality of retention features that are configured to hold battery cells. 
         [0012]    In a further non-limiting embodiment of any of the foregoing assemblies, the cooling channel includes a coolant inlet and a coolant outlet. 
         [0013]    In a further non-limiting embodiment of any of the foregoing assemblies, the cooling channel extends along an undulated path. 
         [0014]    In a further non-limiting embodiment of any of the foregoing assemblies, the undulated path includes a plurality of alternating narrow regions and expanded regions that extend between opposing interior walls of the first retainer section and the second retainer section. 
         [0015]    In a further non-limiting embodiment of any of the foregoing assemblies, the cooling channel extends along a longitudinal axis of the assembly. 
         [0016]    A battery module according to another exemplary aspect of the present disclosure includes, among other things, a battery cell and a battery cooling and retainer assembly configured to both hold the battery cell and cool the battery cell with a coolant that is communicated inside of the battery cooling and retainer assembly. 
         [0017]    In a further non-limiting embodiment of the foregoing battery module, the battery cooling and retainer assembly includes a first retainer section, a second retainer section and a cooling channel between the first retainer section and the second retainer section. 
         [0018]    In a further non-limiting embodiment of either of the foregoing battery modules, at least one of the first retainer section and the second retainer section includes a retention feature that includes spaced apart arms that hold the battery cell. 
         [0019]    In a further non-limiting embodiment of any of the foregoing battery modules, the cooling channel extends along a longitudinal axis inside of a cooling housing of the battery cooling and retainer assembly. 
         [0020]    In a further non-limiting embodiment of any of the foregoing battery modules, a plurality of battery cells are retained within a plurality of pockets of the battery cooling and retainer assembly. 
         [0021]    In a further non-limiting embodiment of any of the foregoing battery modules, the coolant is communicated along an undulated path inside of the battery cooling and retainer assembly. 
         [0022]    In a further non-limiting embodiment of any of the foregoing battery modules, the battery cell cooling and retainer assembly is a monolithic, molded assembly. 
         [0023]    An electrified vehicle according to another exemplary aspect of the present disclosure includes, among other things, a battery pack that includes a plurality of battery modules. At least one of the plurality of battery module includes a plurality of battery cells and a battery cooling and retainer assembly that includes a cooling channel and integrated retention features. 
         [0024]    The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. 
         [0025]    The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]      FIG. 1  schematically illustrates a powertrain of an electrified vehicle. 
           [0027]      FIGS. 2A and 2B  illustrate a battery cooling and retainer assembly of a battery module. 
           [0028]      FIG. 3  is a front view of the battery cooling and retainer assembly of  FIG. 2 . 
           [0029]      FIG. 4  is a bottom view of the battery cooling and retainer assembly of  FIG. 2 . 
           [0030]      FIG. 5  illustrates a first cross-sectional view through a battery cooling and retainer assembly. 
           [0031]      FIG. 6  illustrates a second cross-sectional view through a battery cooling and retainer assembly. 
           [0032]      FIG. 7  illustrates a battery cooling and retainer assembly according to another embodiment of this disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    This disclosure relates to a battery cooling and retainer assembly for a battery module that can accommodate one or more battery cells. The battery cooling and retainer assembly includes a cooling channel as well as integrated battery cell retention features. In other words, the battery cooling and retainer assembly is configured to simultaneously cool and retain battery cells of the battery module in a single, monolithic part. These and other features are discussed in greater detail herein. 
         [0034]      FIG. 1  schematically illustrates a powertrain  10  of an electrified vehicle  12 . The electrified vehicle  12  may be a HEV, PHEV, BEV, or any other vehicle. In other words, this disclosure is not limited to any particular type of electrified vehicle. 
         [0035]    The powertrain  10  includes a drive system having at least a motor  36  (i.e., an electric machine) and a battery pack  50 . The battery pack  50  may include a high voltage battery that is capable of outputting electrical power to operate the motor  36 . Although not shown in  FIG. 1 , the battery pack  50  may be made up of multiple battery modules that are electrically connected to one another. 
         [0036]    The drive system generates torque to drive one or more sets of vehicle drive wheels  30  of the electrified vehicle  12 . For example, the motor  36  can powered by the battery pack  50  and employed to electrically drive the vehicle drive wheels  30  by outputting torque to a shaft  46 . Of course, this view is highly schematic. It should be appreciated that the powertrain  10  of the electrified vehicle  12  could employ additional components, including but not limited to, an internal combustion engine, a generator, a power transfer unit, and one or more control systems. 
         [0037]      FIGS. 2A ,  2 B and  3  illustrate a battery cooling and retainer assembly (hereinafter “assembly”)  60 . The assembly  60  may be part of a battery module  100  that includes one or more battery cells  62 . One or more of such battery modules  100  may make up the battery pack  50  illustrated in  FIG. 1 . The battery cells  62  of the battery module  100  are illustrated in  FIGS. 2A and 3  but are omitted in  FIG. 2B  to better illustrate certain features of the assembly  60 . 
         [0038]    The assembly  60  is scalable in size to accommodate any number of battery cells  62  and is not necessarily limited to the size, shape and configuration of this illustrated embodiment. For example, the assembly  60  could accommodate either a single battery cell  62  or a multitude of battery cells  62  within the scope of this disclosure. 
         [0039]    The assembly  60  may be a single piece, unitary part. For example, the assembly  60  may be a monolithic structure. In one non-limiting embodiment, the assembly  60  is an injection molded plastic part. In another embodiment, the assembly  60  is a blow molded plastic part (see  FIG. 7 ). However, the assembly  60  could be constructed using other manufacturing techniques and other materials within the scope of this disclosure. 
         [0040]    The assembly  60  may include a first retainer section  64  and a second retainer section  66  that extend along a longitudinal axis A of the assembly  60 . The first retainer section  64  is disposed on a first side  68  of a cooling housing  70  and the second retainer section  66  is disposed on a second, opposite side  72  of the cooling housing  70 . The cooling housing  70  houses a cooling channel  74  (shown in phantom lines in  FIG. 2A  and is best illustrated in the cross-sectional views of  FIGS. 5 and 6 ) that extends inside of the cooling housing  70 . In other words, in one embodiment, the cooling channel  74  is an internal cooling passage disposed inside of the assembly  60 . 
         [0041]    The cooling channel  74  includes a coolant inlet  88  and a coolant outlet  90 . The coolant inlet  88  feeds coolant C into the cooling channel  74  and the coolant outlet  90  expels the coolant C from the cooling channel  74  (see  FIGS. 2A and 3 ). 
         [0042]    Both the first retainer section  64  and the second retainer section  66  may include one or more retention features  76  for positioning and holding the battery cells  62  of the battery module  100 . The retention features  76  include spaced apart arms  78  that extend in a direction away from the cooling housing  70  (i.e., transverse to the longitudinal axis A). The spaced apart arms  78  partially circumscribe a pocket  84  that is sized to receive a battery cell  62 . 
         [0043]    In one embodiment, the spaced apart arms  78  vertically span across a distance between an open top  80  and a shelf  82  (see  FIG. 2B ). The shelves  82  extend horizontally between adjacent spaced apart arms  78  to positively locate the battery cells  62  at a common height H 1 . The height H 1  may be greater than a height H 2  of the spaced apart arms  78  between the open tops  80  and the shelves  82  (see  FIG. 3 ). 
         [0044]    In one embodiment, the pockets  84  are semi-cylindrical shaped to accommodate a corresponding cylindrical shaped battery cell  62 . However, the pockets  84  may be shaped in any other manner to accommodate battery cells  62  of varying sizes, shapes and configurations. 
         [0045]    In one non-limiting embodiment, as is illustrated in  FIG. 2B , the spaced apart arms  78  are flexible between a collapsed position and a flexed position such that the battery cells  62  may be snap-fit onto the assembly  60 . The spaced apart arms  78  may flex in a first direction D 1  to move to the flexed position (in order to receive a battery cell  62 ) and a second, opposite direction D 2  to move to the collapsed position. In the collapsed position, the spaced apart arms  78  may act to squeeze (i.e., apply a compressive force against) the battery cells  62  such that the battery cells  62  are held securely in place. 
         [0046]      FIG. 4  illustrates a bottom view of the assembly  60 . The first retainer section  64  and the second retainer section  66  may meet together at a seam  86  of the assembly  60 . In one non-limiting manufacturing method, the first retainer section  64  and the second retainer section  66  are injection molded (or blow molded) as separate halves and subsequently fused together at the seam  86  via an ultrasonic welding procedure to form the monolithic assembly  60 . Alternatively, the assembly  60  may be molded as a single, unitary piece without any necessary secondary assembly operations. 
         [0047]      FIGS. 5 and 6 , with continued reference to  FIGS. 2A ,  2 B and  3 , illustrate additional features of the cooling channel  74  of the assembly  60 . In one embodiment, the cooling channel  74  is a hollow space disposed between the first retainer section  64  and the second retainer section  66 . The cooling channel  74  may extend in the direction of the longitudinal axis A through a center of the assembly  60 . However, it is not necessary for the cooling channel  74  to extend through the exact center of the assembly  60 . 
         [0048]    The cooling channel  74  is fed with a coolant C via the coolant inlet  88 . The coolant C may be sourced from any location of the electrified vehicle. The coolant C may then circulate inside the cooling channel  74  prior to exiting the coolant outlet  90  (see  FIG. 3 ). The coolant C that exits the coolant outlet  90  may be communicated to a manifold (not shown) and returned to its source as part of a closed-loop system. 
         [0049]    As best illustrated in the non-limiting embodiment of  FIG. 6 , the cooling channel  74  extends along an undulated path  92 . The undulated path  92  may include a plurality of alternating narrow regions NR and expanded regions ER that extend between opposing interior walls  94  of the first and second retainer sections  64 ,  66 . The expanded regions ER are wider than the narrow regions NR. As the coolant C is circulated along the undulated path  92  through the narrow regions NR and the expanded regions ER, heat is removed from the interior walls  94  to cool the battery cells  62 . 
         [0050]      FIG. 7  illustrates another battery cooling and retainer assembly (hereinafter “assembly”)  160 . In this disclosure, like reference numbers designate like elements where appropriate and reference numerals with the addition of  100  or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding original elements. 
         [0051]    In this embodiment, the assembly  160  is a blow molded assembly. The assembly  160  is substantially similar to the assembly  60  of  FIGS. 2-6 . For example, the assembly  160  may include a first retainer section  164 , a second retainer section  166 , and a cooling channel  174  (shown in phantom) disposed between the first and second retainer sections  164 ,  166 . One or both of the first and second retainer sections  164 ,  166  may include retention features  176  for holding battery cells  62 . However, in this embodiment, the retention features  176  of the assembly  160  exclude shelves (see feature  82  of  FIGS. 2B ). The battery cells  62  of this embodiment are snap-fit in place by spaced apart arms  178 . 
         [0052]    Although the different non-limiting embodiments are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. 
         [0053]    It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. 
         [0054]    The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.