Patent Publication Number: US-2018034122-A1

Title: Battery thermal management assembly

Description:
INCORPORATION BY REFERENCE 
     This application claims priority under 35 U.S.C. §119 to U.S. Provisional Application No. 62/369,734, filed on Aug. 1, 2016, which is incorporated by reference herein in its entirety. 
    
    
     FIELD OF INVENTION 
     The present disclosure relates to a battery, and more particularly relates to a thermal management assembly for a battery. 
     BACKGROUND 
     Electric vehicles include battery packs to power a vehicle&#39;s electrical components, such as the motor, engine, control systems. Precise control systems are required for these battery packs to ensure that the battery assembly is maintained at an ideal temperature. Batteries perform optimally at particular charging temperatures, operating temperatures, and other characteristic temperature ranges. One known way to control the temperature of a vehicle&#39;s battery pack is to rely on the vehicle&#39;s central thermal management loop, which typically includes a radiator and a liquid/gas coolant in a thermal circuit. Electric vehicles can include interchangeable and rechargeable battery packs. These battery packs must be removed and re-installed by users as a charge level of a specific battery pack decreases or is depleted. It is time consuming and cumbersome for users to remove these battery packs due to a shared liquid/gas coolant connection with the vehicle&#39;s central thermal management loop. Due to the shared liquid/gas coolant connection, issues with leakage, aeration, and other performance and reliability issues occur during replacement of the battery pack. 
     It would be desirable to provide a battery pack for an electric vehicle that does not share a physical liquid/gas coolant connection with the vehicle&#39;s central thermal management loop, and it would also be desirable to provide an efficient thermal management arrangement for the vehicle&#39;s battery pack. 
     SUMMARY 
     A battery thermal management assembly is provided. The battery thermal management assembly includes a vehicle thermal assembly including a first thermal exchange module arranged adjacent to a first thermal exchange circuit. A battery pack includes a plurality of battery modules, a second thermal exchange circuit including heat transfer conduits contacting the plurality of battery modules, and a second thermal exchange module arranged adjacent to the second thermal exchange circuit. The second thermal exchange module is positioned facing the first thermal exchange module. The first thermal exchange circuit and the second thermal exchange circuit are isolated from each other. A thermal gap pad is arranged between the first thermal exchange module and the second thermal exchange module. Based on this configuration, the thermal exchange circuit for the vehicle thermal assembly is isolated from the thermal exchange circuit of the battery pack. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing Summary and the following detailed description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the invention. In the drawings: 
         FIG. 1A  is a schematic illustration of a battery thermal management assembly according to a first embodiment. 
         FIG. 1B  is another schematic illustration of a battery thermal management assembly according to the first embodiment. 
         FIG. 2  is a schematic illustration of a battery thermal management assembly according to a second embodiment. 
         FIG. 3  is a schematic illustration of a battery thermal management assembly according to a third embodiment. 
         FIG. 4  is a schematic illustration of a battery thermal management assembly according to a fourth embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In one embodiment, a battery thermal management assembly  10  is illustrated in  FIGS. 1A and 1B . As shown in  FIGS. 1A and 1B , the battery thermal management assembly  10  includes a vehicle thermal assembly  18  and a battery pack  14 . 
     The vehicle thermal assembly  18  is contained integrally within the vehicle, while the battery pack  14  is an easily and readily removable and interchangeable component. A user can quickly and reliably replace battery packs  14  as the existing battery pack  14  depletes its charge or otherwise must be replaced. A new, fully charged and functioning battery pack  14  can then be installed into the vehicle. As discussed above, replacing battery packs in known arrangements is unreliable, messy, cumbersome, and time-consuming because known arrangements include a battery pack integrated within the vehicle thermal assembly  18 . 
     As shown in  FIGS. 1A and 1B , the battery pack  14  is completely separated from the internal components of the vehicle thermal assembly  18 , i.e. a coolant circuit, radiator, etc. The battery pack  14  and the vehicle thermal assembly  18  are completely separately positioned and arranged, and do not have a shared coolant connection. The vehicle thermal assembly  18  of  FIGS. 1A and 1B  includes a first thermal exchange module  22  positioned directly adjacent to a first thermal exchange circuit  19 .  FIGS. 1A and 1B  illustrate a schematic view of a vehicle thermal assembly  18 . One of ordinary skill in the art would recognize that the cooling and heating components of the vehicle thermal assembly  18  can be varied depending on a specific vehicle or application. 
     The vehicle thermal assembly  18  includes a first pump  12  for circulating coolant within the first thermal exchange circuit  19 . The term coolant as used in this application includes any liquid, gas, or other medium that can be used to transfer heat. The vehicle thermal assembly  18  also includes a radiator  16 . Although not specifically illustrated, the radiator  16  can include an evaporator, condenser, compressor, fan, blower, or any other known heating/cooling components. The term radiator can include any heat exchanger as understood by those of ordinary skill in the art. 
     The vehicle thermal assembly  18  is in communication with a plurality of vehicle components  15   a , such as the motor, central controller, generator, converter, charger, etc. The plurality of vehicle components  15   a  are generically illustrated as a single box in  FIGS. 1A and 1B , but those of ordinary skill in the art would recognize from the present disclosure that any number and variety of vehicle components can be arranged in communication with the vehicle thermal assembly  18 . A first sensor  17  is also provided in communication with the first thermal exchange circuit  19  to monitor coolant within the first thermal exchange circuit  19 . The radiator  16  is adjusted to control the heating or cooling of coolant within the first thermal exchange circuit  19  based on data from the first sensor  17 . The first sensor  17  can detect a temperature of the coolant, flow rate of the coolant, and other characteristics of the coolant. Essentially, the vehicle thermal assembly  18  serves as a central heat transfer component for the entire vehicle. 
     The battery pack  14  is arranged adjacent to the vehicle thermal assembly  18 . The battery pack  14  includes a plurality of battery modules  20  arranged within a housing  28 . Each of the plurality of battery modules  20  is independently controlled and used to power the vehicle. A second thermal exchange circuit  30  includes heat transfer conduits  32  that contact each of the plurality of battery modules  20  to provide a heating or cooling effect. The housing  28  completely encloses the plurality of battery modules  20  and only partially encloses the second thermal exchange circuit  30 . 
     The battery pack  14  is in electrical communication with the electrical components  15   b  of the vehicle, such as the motor, engine, electric control units, electric display units, electric power systems. The electrical components  15   b  are generically illustrated in  FIG. 1A . A communication pathway can be established between the vehicle components  15   a  and the electrical components  15   b.    
     The heat transfer conduits  32  can include heat transfer pipes or channels. The second thermal exchange circuit  30  is similar to the first thermal exchange circuit  19  and can include a second pump  24  for directing coolant within the second thermal exchange circuit  30 . The first thermal exchange circuit  19  and the second thermal exchange circuit  30  are completely isolated from each other. The first thermal exchange circuit  19  and the second thermal exchange circuit  30  do not have any common coolant conduits and are completely separated from each other. 
     A second sensor  25  is also provided within the housing  28  for monitoring the coolant within the second thermal exchange circuit  30 . The second sensor  25  functions similarly to the first sensor  17  described above. The battery pack  14  includes a second thermal exchange module  26  that is arranged directly facing the first thermal exchange module  22 . The thermal exchange modules  22 ,  26  are aligned such that heat is transferred between the thermal exchange modules  22 ,  26 . 
     The first and second thermal exchange modules  22 ,  26  provide the only heat exchange interface between the battery pack  14  and the vehicle thermal assembly  18 . The first and second thermal exchange modules  22 ,  26  can include any electric/thermal component capable of heating or cooling. The first and second thermal exchange modules  22 ,  26  serve as a heat pump for the assembly  10 . One known type of thermal exchange module includes a thermoelectric module. Known thermoelectric modules include a circuit comprising thermoelectric materials that generate electricity from heat directly, and/or can supply heat through the application of current or voltage. Therefore, the thermoelectric module can be used for heating and cooling, as well as power generation. In one embodiment, the thermoelectric module includes n-type and p-type doped semiconductor materials that are connected electrically in series and thermally in parallel. Typically, the semiconductor material and the thermoelectric materials are arranged between two ceramic substrates, which both provide mechanical structure as well as electrically insulating the elements within the thermoelectric module from each other and the external mounting surface. Any variety of substrate shape, substrate materials, thermoelectric material, internal components, mounting arrangement, and other characteristics can be varied for the first and second thermal exchange modules  22 ,  26 . 
     The first and second thermal exchange modules  22 ,  26  bridge a thermal exchange gap between the battery pack  14  and the vehicle thermal assembly  18 , such that the battery pack  14  can be heated or cooled. The battery pack  14  is heated if the battery pack  14  is below a certain temperature, or is cooled if the battery pack  14  is above a certain temperature. Each battery pack  14  has an ideal target operating temperature, ideal target charging temperature, etc. These temperatures are selected to ensure that the battery pack  14  is maintained at an optimal temperature. In one embodiment, a target temperature of the battery pack  14  is 70 degrees Fahrenheit. The target temperature can include a range, such as between 60-80 degrees Fahrenheit. The target temperature varies depending on the specifications of a particular battery pack. 
     A thermal gap pad  34  is arranged between the first thermal exchange module  22  and the second thermal exchange module  26 . The thermal gap pad  34  is preferably arranged directly in contact with the first thermal exchange module  22  and the second thermal exchange module  26 . The thermal gap pad  34  provides a heat transfer interface between the battery pack  14  and the vehicle thermal assembly  18 . The material of the thermal gap pad  34  is selected to provide an effective thermal exchange interface. The thermal gap pad  34  may be comprised of an elastomer, silicone elastomer, or other suitable thermal gap material. 
     A thermoelectric control assembly  36  is also provided in communication with the first thermal exchange module  22  and the second thermal exchange module  26 . The thermal exchange control unit  36  includes an electric control unit  38 , a power supply unit  40 , a thermoelectric control sensor  44 , and a thermoelectric generator  46 . The electric control unit  38  sends signals to the first thermal exchange module  22  and the second thermal exchange module  26  to either heat, cool, or absorb thermal energy. The power supply unit  40  is provided to supply power to the thermoelectric control assembly  36  and the first thermal exchange module  22  and the second thermal exchange module  26 . The thermoelectric control sensor  44  detects the temperatures of the first thermal exchange module  22  and the second thermal exchange module  26 . Collectively, the components of the thermoelectric control assembly  36  controls the functions of the first thermal exchange module  22  and the second thermal exchange module  26 . The term “functions” refers to heating, cooling, absorbing heat, and/or converting heat into electrical energy or power. A second plurality of vehicle components  15 ′ can also be provided in communication with the thermoelectric control assembly  36 . The thermoelectric control assembly  36  can provide power to the second plurality of vehicle components  15 ′ based on the absorbed thermal energy from the first thermal exchange module  22  and the second thermal exchange module  26 . The second plurality of vehicle components  15 ′ are separately illustrated from the plurality of vehicle components  15   a , but can include the same vehicle components. 
     A flow of coolant is illustrated in  FIGS. 1A and 1B . In  FIG. 1A , a first direction of coolant flow is indicated by a plurality of arrows in the second thermal transfer circuit  30 .  FIG. 1B  illustrates an identical configuration as  FIG. 1A , however the coolant flow is in a reverse direction compared to  FIG. 1A . The control units and pumps regulate the flow direction, speed, volume, etc., of coolant. A first thermal flow  42  is illustrated in a first direction in  FIG. 1A  and a second thermal flow  42 ′ is illustrated in a second direction in  FIG. 1B . The thermal flows  42 ,  42 ′ can be reversed depending on whether the battery pack  14  should be heated or cooled. 
       FIG. 2  illustrates a second embodiment of a battery thermal management assembly  110 . The components not specifically discussed herein with respect to  FIG. 2  are identical to  FIGS. 1A and 1B  except the reference numerals used in  FIG. 2  are increased by 100. In  FIG. 2 , the battery pack  114  includes a plurality of supplemental thermal exchange modules  150 . The supplemental thermal exchange modules  150  are each arranged adjacent to a respective one of the plurality of battery modules  120 . Each of the plurality of battery modules  120  can include a secondary thermal exchange control unit  170 , having a secondary electric control unit  172 , a secondary power supply unit  174 , a secondary thermoelectric control sensor  176 , and a secondary thermoelectric generator  178 . Each of the secondary thermal exchange control units  170  can be independently activated and controlled. The embodiment of  FIG. 2  differs from the embodiment of  FIGS. 1A and 1B  in that each of the battery modules  120  includes its own thermal control assembly. In this embodiment, a targeted cooling or heating can occur for individual battery modules of the plurality of battery modules  120 . Otherwise, the structure, function, and features of the vehicle thermal assembly  118  and the battery pack  114  of  FIG. 2  are identical to the embodiment of  FIGS. 1A and 1B . 
       FIG. 3  illustrates a third embodiment of a battery pack  214 . The components not specifically discussed herein with respect to  FIG. 4  are identical to  FIGS. 1A and 1B  except the reference numerals used in  FIG. 4  are increased by 200. The battery pack  214  includes a plurality of battery modules  220  and a plurality of thermal exchange modules  250  arranged within a common housing  218 . Each one of the plurality of thermal exchange modules  250  is arranged adjacent to a respective one of the plurality of battery modules  220 . A heat sink  260  is arranged adjacent to the housing  218 . Preferably, the heat sink  260  is integrally formed with the housing  218 . The heat sink  260  includes a plurality of fins  262  that project away from the battery pack  214  to promote thermal transfer away from the battery pack  214 . 
     The battery pack  214  can include a plurality of individual thermal exchange control units, or a single common thermal exchange control unit. A simplified illustration is provided in  FIG. 3  showing a thermal exchange control unit  236  including a secondary electric control unit  238 , a secondary power supply unit  240 , a secondary thermoelectric control sensor  244 , and a secondary thermoelectric generator  246 . The thermal exchange control unit  236  is connected to a plurality of vehicle components  215 . 
     Although not specifically illustrated in  FIG. 3 , one of ordinary skill in the art would recognize that the battery pack  214  can include a thermal exchange circuit, similar to the thermal exchange circuit  30  of  FIGS. 1A and 1B . 
       FIG. 4  illustrates a schematic representation of a fourth embodiment of a battery pack  314  having a housing  328  and a plurality of battery modules  320   a - 326   a ,  320   b - 326   b ,  320   c - 326   c . The plurality of battery modules are arranged in rows that are spaced apart from each other. As shown in  FIG. 4 , the first row includes batteries  320   a ,  320   b ,  320   c , the second row includes batteries  321   a ,  321   b ,  321   c , etc. Each row can be independently controlled (i.e. heated, cooled) such that a temperature of the first row of batteries  320   a ,  320   b ,  320   c  can be varied from the last row of batteries  326   a ,  326   b ,  326   c . In one embodiment, the front side of the housing  328  includes the first row of batteries  320   a ,  320   b ,  320   c , and the rear end of the housing  328  includes the last row of batteries  326   a ,  326   b ,  326   c . During operation, the front side of the housing  328  will encounter more ambient cooling air as the vehicle travels in the forward direction. Due to this ambient cooling air, the front row of batteries  320   a ,  320   b ,  320   c  will typically require less cooling and the back row of batteries  326   a ,  326   b ,  326   c  will typically require more cooling. The battery pack  314  can be selectively cooled such that the last row of batteries  326   a ,  326   b ,  326   c  are cooled more than the first row of batteries  320   a ,  320   b ,  320   c.    
     The battery thermal management assembly of the present disclosure helps mitigate issues caused by a thermal runaway event. The thermal exchange modules can be used as a fire suppression element during thermal runaway events. In an overdrive mode, the thermal exchange modules can sustain increased temperature loads cause by thermal runaway, and allow an operator of a vehicle to bring the vehicle to a safe location before the thermal runaway inflicts serious damage on the vehicle. 
     Having thus described the presently preferred embodiments in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the invention, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiments and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.