Patent ID: 12243995

DETAILED DESCRIPTION

Aspects of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings. The apparatus disclosed herein can, however, be realized in many different forms and should not be construed as being limited to the aspects set forth herein. Like numbers in the drawings refer to like elements throughout.

The terminology used herein is for the purpose of describing particular aspects of the disclosure only, and is not intended to limit the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Some of the example embodiments presented herein are directed towards a system comprising a plurality of battery modules with a cold plate for cooling the plurality of battery modules. Each battery module comprises battery cells, which may be prismatic cells (in particular lithium-ion secondary battery cells) and the example embodiments of the system may be used in an energy storage system, ESS, or in an automotive application.

FIG.1is a perspective view of a first example of a battery module10which in this example comprises five battery cells11with a bottom surface15and a top side16. The module also comprises two side plates12. Each side plate12is in this example L-shaped and together they are configured to position the battery cells11adjacent to each other and maintain the form of the battery module10, e.g. using an adhesive. Each side plate12comprises a side portion13and a protruding lower edge14, wherein the battery cells are stacked with the bottom surface15supported by the protruding lower edge14and the side portion13extends in a direction perpendicular to the bottom surface15of the battery cells. The top side16may also comprise terminals17and exhaust valves (not shown). For completeness, it is noted that a battery module may comprise additional components, which are not shown inFIG.1in order to not obscure the inventive concept. For example, cell spacers may be placed between each pair of battery cells to provide electrical insulation and improve the compression uniformity along the length of the battery stack. Further, end plates may be provided at each end of the battery stack, combining with the side plates to form a complete enclosure for the cells. Yet further, the cell terminals are typically attached to bus bars, e.g. via welding, in order to provide an electrical connection with the cells to enable charging and discharging. A cell sensing assembly may be provided on top of the cell stack with temperature and/or voltage sensors which are attached to the cells or bus bars e.g. using a wire harness. A top lid may additionally be provided over the cell sensing assembly to protect and insulate the enclosure.

This design reduces the amount of material needed to maintain the battery cells in a stacked configuration within the battery module. Furthermore, the weight of the battery module is also reduced as well as exposing a large portion of the bottom surface of the battery cells, which may be used to cool the battery cells in an efficient way.

FIG.2is an illustrative top view of a first example embodiment of a cold plate20for four battery modules10(indicated by dotted lines inFIG.2), where each battery cell of the battery module has an exposed bottom surface15intended to be cooled by the cold plate. The cold plate20comprises a base plate21provided with cooling channels which are schematically illustrated with arrows28and29in two cooling loops. Furthermore, the cold plate20comprises an inlet port24configured to provide cooling media to a first cooling loop28and to a second cooling loop29via an inlet manifold25. In addition, the cold plate20comprises an outlet port26configured to receive cooling media from the first cooling loop28and the second cooling loop29via an outlet manifold27. The cold plate further comprises two cut-outs22and23configured to house the protruding lower edge14of each battery module10in order for the bottom surface15of the battery cells11to be arranged close to the cooling loops28,29of the cold plate20. The respective cut-out22and23is in this example illustrated with a closed perimeter.

FIG.3ais an illustrative top view of a second example embodiment of a cold plate30for two battery modules10(indicated by dotted lines inFIG.3), where each battery cell within the battery module has a bottom surface15intended to be cooled by the cold plate30. The cold plate30comprises a base plate31provided with cooling channels which are schematically illustrates with arrows38and39in two cooling loops. Furthermore, the cold plate30comprises an inlet port24configured to provide cooling media to a first cooling loop38and to a second cooling loop39via an inlet manifold25. In addition, the cold plate30comprises an outlet port26configured to receive cooling media from the first cooling loop38and the second cooling loop39via an outlet manifold27. The cold plate further comprises one cut-out32configured to house the protruding lower edge14of each battery module10in order for the bottom surface15of the battery cells11to be arranged close to the cooling loops38,39of the cold plate30. The cut-out32is in this example illustrated with a closed perimeter.

FIG.3bis a cross-sectional view along A-A of the cold plate ofFIG.3awith a cross-sectional view of two battery modules10ofFIG.1. The bottom surfaces15of the battery cells11of each battery module10are positioned adjacent to the cooling loops in the base plate31since one of the protruding lower edges14of each battery module10is positioned in the cut-out32.

FIG.4is an illustrative top view of a third example embodiment of a cold plate40for four battery modules10(indicated by dotted lines inFIG.4), each battery cell of the battery module has an exposed bottom surface intended to be cooled by the cold plate40. The cold plate40comprises a base plate41provided with cooling channels which are schematically illustrates with arrows28and29in two cooling loops. Furthermore, the cold plate40comprises an inlet port24configured to provide cooling media to a first cooling loop28and to a second cooling loop29via an inlet manifold25. In addition, the cold plate40comprises an outlet port26configured to receive cooling media from the first cooling loop28and the second cooling loop29via an outlet manifold27. The cold plate further comprises one cut-out42configured to house one of the protruding lower edges14of each battery module10in order for the bottom surfaces15of the battery cells11to be arranged close to the cooling loops28,29of the cold plate40. The cut-out42is in this example illustrated with an open perimeter.

FIG.5is an illustrative top view of a fourth example embodiment of a cold plate50for four battery modules10(indicated by dotted lines inFIG.4), each battery cell of the battery module has an exposed bottom surface intended to be cooled by the cold plate50. The cold plate50comprises a base plate51provided with cooling channels which are schematically illustrates with arrows28and29in two cooling loops. Furthermore, the cold plate50comprises an inlet port24configured to provide cooling media to a first cooling loop28and to a second cooling loop29via an inlet manifold25. In addition, the cold plate50comprises an outlet port26configured to receive cooling media from the first cooling loop28and the second cooling loop29via an outlet manifold27. The cold plate further comprises two cut-outs23and52configured to house one of the protruding lower edges14of each battery module10in order for the bottom surface15of the battery cells11to be arranged close to the cooling loops28,29of the cold plate50. A first cut-out23is in this example illustrated with a closed perimeter, and a second cut-out42is in this example illustrated with an open perimeter.

It should be noted that the cooling channels28,29;38,39in the above described example embodiments may be configured to regulate the flow of cooling media in each cooling loop. This may be achieved by letting the cooling channels have equal height (to ensure that the cold plate has a uniform thickness) and varying width to regulate the flow of cooling media through the cooling channels.

An implementation of a cold plate60is illustrated in connection withFIG.6, in which each cooling loop is divided into cooling sections connected via transport sections and each cooling section is configured to be positioned adjacent to the surface of the battery cells11in the respective battery module10.

FIG.6is a top view of a cold plate60, which is an implementation of the first example embodiment of a cold plate described in connection withFIG.2a cold plate20, for four battery modules10(indicated by dotted lines inFIG.6), each battery cell of the battery module has an exposed bottom surface intended to be cooled by the cold plate60. The cold plate60comprises a base plate61provided with cooling channels in two cooling loops68and69. Furthermore, the cold plate60comprises an inlet port24configured to provide cooling media to a first cooling loop68and to a second cooling loop69via an inlet manifold25. In addition, the cold plate60comprises an outlet port26configured to receive cooling media from the first cooling loop68and the second cooling loop69via an outlet manifold27. The cold plate further comprises two cut-outs22and23configured to house one of the protruding lower edges14of each battery module10in order for the bottom surface15of the battery cells11to be arranged close to the cooling loops68,69of the cold plate60. The respective cut-out22and23is in this example illustrated with a closed perimeter.

Each cooling loop68and69comprises several cooling sections62a-62dand63a-63dconnected via transport sections64a-64c,65a-65c, wherein each cooling section62a-62dand63a-63dis configured to be positioned adjacent to the battery module10. The inlet port24is in this implementation positioned closer to the first cooling loop68compared to the second cooling loop69, and the flow of cooling media at the cooling section62aclosest to the inlet port24is higher than the flow of cooling media in the cooling section62dclosest to the outlet port26.

The second cooling loop69is connected to the inlet port24via a first manifold25and connected to the outlet port26via a second manifold27, wherein the flow of cooling media in the cooling section63aclosest to the inlet manifold25is the same as the flow of cooling media in the cooling section63dclosest to the outlet manifold27.

Each transport section64a-64cand65a-65cis configured to balance the flow of media between the first cooling loop68and second cooling loop69. This may be performed by reducing the width of the cooling channel in the transport sections compared to the adjacent cooling sections. For instance, the first cooling loop68closest to the inlet port24has a restricted portion in a first part of the cooling loop. The purpose is to increase the pressure in the first part to ensure an equal flow in both cooling loops. Without this restriction, the cooling media flow in the first cooling loop68would be higher than the cooling media flow in the second cooling loop69since the cooling media will take the path of least resistance.

Furthermore, as illustrated, the transport sections64a-64c,65a-65care implemented as restricted portions in the cooling loops. In the illustrative example inFIG.6, the first cooling loop has three restricted portions, but other designs are possible.

It is advantageous to implement the restricted portions in the transport sections situated between the battery modules10and not directly underneath the battery cells, otherwise the cooling effect could be reduced. This is illustrated inFIG.6where transport sections64a,64c,65aand65c(implemented with restricted portions) are positioned in the middle (between two modules), transport sections64band65bare positioned at the 180 degree turn of each cooling loop and restricted portions are positioned at the end of each cooling loop near the outlet port26.

For instance, the ratio of the restricted portions in the transport sections64a-64b,65a-65cto the wider portions in the cooling sections62a-62d,63a-63dshould be in the range 30-50%. As an example, if there are several restricted portions a first portion could be 30% and a second one could be 50% of the width.

The flow design with restricted portions (in combination with the cutouts22,23) enable the use of one large cold plate61for several modules10instead of separate cold plates for each module.

FIG.7is a perspective view of an energy storage system, ESS,70comprising a cabinet71with a controller72, at least one battery system75and an inlet73and outlet74for cooling media. In this example, the ESS70comprises sixteen battery systems75. Each battery system75comprises a plurality of battery modules10and a cold plate provided with at least one cut-out configured to house at least one of the protruding lower edges of each battery module10. The battery systems may be stacked and/or arranged on shelves. The inlet/outlet of the cooling media is connected to the inlet port24and the outlet port26of each cold plate via a cabinet manifold (not shown) to provide adequate cooling properties to the battery cells within the battery modules. The inlet73/outlet74may be positioned on the same cabinet wall (as illustrated) or on different cabinet walls. Furthermore, the inlet73/outlet74may be positioned on any cabinet wall, e.g. the rear wall.

FIG.8ais an perspective view of a second example of parts of a battery module80which in this example comprises ten battery cells81with a bottom surface15and a top side16. The battery module further comprises two side plates12and two end plates (82). Each side plate12is in this example L-shaped and together they are configured to position the battery cells11adjacent to each other and maintain the form of the battery module10, e.g. using an adhesive.

Each side plate12comprises a side portion13and a protruding lower edge14, wherein the battery cells are stacked with the bottom surface15supported by the protruding lower edge14and the side portion13extends in a direction perpendicular to the bottom surface15of the battery cells. Each end plate82extends in a direction perpendicular to the bottom surface15and the side portion13of the side plates12, wherein each end plate82covers opposing sides of the battery module (80). The top side16may also comprise terminals and exhaust valves (not shown).

This design has the same advantages as the first example embodiment of the battery module described in connection withFIG.1, and also increases the structural stability compared to the first example of the battery module10inFIG.1without increasing the volume of the complete system when placed on a cold plate as illustrated inFIG.8b.

FIG.8bis a side view of a system85where two battery modules80are placed on the cold plate ofFIG.4. The bottom surface15of the battery cells81of each battery module80is positioned adjacent to the cooling loops in the base plate41since one of the protruding lower edges14of each battery module80is positioned in the cut-out42.

This disclosure relates to a system comprising: a plurality of battery modules, wherein each battery module comprises a plurality of battery cells and two side plates, each side plate having a protruding lower edge, wherein the battery cells are stacked with a bottom surface supported by the protruding lower edge of the two side plates; and a cold plate for cooling the plurality of battery modules; wherein the cold plate comprises: a base plate provided with cooling channels, wherein the base plate is thermally connected to the bottom surface of the battery cells in each battery module; an inlet port for feeding cooling media via the cooling channels to an outlet port, and at least one cut-out configured to house one of the protruding lower edges of the side plates.

According to some aspects, each of the two side plates further comprises a side portion extending in a direction perpendicular to the bottom surface of the battery cells, wherein each side plate further covers opposing sides of the battery module.

According to some aspects, each battery module further comprises two end plates extending in a direction perpendicular to the bottom surface and the side portion of the side plates, wherein each end plate covers opposing sides of the battery module.

According to some aspects, each side plate has an L-shape. Other shapes, e.g. a bracket shape, with a protruding lower edge may be used that supports the bottom surface of the battery cells in a battery module.

According to some aspects, the at least one cut-out comprises a cut-out with a closed perimeter.

According to some aspects, the at least one cut-out comprises a cut-out with an open perimeter.

According to some aspects, the cooling channels have equal height and varying width to regulate the flow of cooling media through the cooling channels.

According to some aspects, terminal connections are provided on a top surface opposite to the bottom surface.

According to some aspects, the cooling channels comprises a first cooling loop.

According to some aspects, the cooling channels comprises an inlet manifold and an outlet manifold to provide cooling media from the inlet port to the outlet port via the first cooling loop and a second cooling loop, wherein the at least one cut-out is arranged between the first cooling loop and the second cooling loop.

According to some aspects, the cooling channels are configured to regulate the flow of cooling media in each cooling loop.

According to some aspects, the cooling channels have equal height and varying width to regulate the flow of cooling media in each cooling loop.

According to some aspects, each cooling loop comprises several cooling sections connected via transport sections, wherein each cooling section is positioned adjacent to the battery module, wherein the inlet port is positioned closer to the first cooling loop compared to the second cooling loop, and the flow of cooling media at the cooling section closest to the inlet port is higher than the flow of cooling media in the cooling section closest to the outlet port.

According to some aspects, the second cooling loop is connected to the inlet port via the inlet manifold and connected to the outlet port via the outlet manifold, wherein the flow of cooling media in the cooling section closest to the first manifold is the same as the flow of cooling media in the cooling section closest to the second manifold.

According to some aspects, each transport section is configured to balance the flow of media between the first cooling loop and second cooling loop.

This disclosure also relates to a cold plate for cooling a plurality of battery modules in a system as disclosed above, wherein each battery module comprises a plurality of battery cells and two side plates, each side plate having a protruding lower edge, wherein the battery cells are stacked with a bottom surface supported by the protruding lower edge of the two side plates, wherein the cold plate comprises:a base plate provided with cooling channels, wherein the base plate is configured to be thermally connected to the bottom surface of the battery cells in each battery module;an inlet port for feeding cooling media via the cooling channels to an outlet port, andat least one cut-out configured to house one of the protruding lower edges of the side plates.

According to some aspects, the at least one cut-out comprises a cut-out with a closed perimeter.

According to some aspects, the at least one cut-out comprises a cut-out with an open perimeter.

According to some aspects, the cooling channels have equal height and varying width to regulate the flow of cooling media through the cooling channels.

According to some aspects, the cooling channels comprises a first cooling loop.

According to some aspects, the cooling channels comprises an inlet manifold and an outlet manifold to provide cooling media from the inlet port to the outlet port via the first cooling loop and a second cooling loop, wherein the at least one cut-out is arranged between the first cooling loop and the second cooling loop.

According to some aspects, the cooling channels are configured to regulate the flow of cooling media in each cooling loop.

According to some aspects, the cooling channels have equal height and varying width to regulate the flow of cooling media in each cooling loop.

According to some aspects, each cooling loop comprises several cooling sections connected via transport sections, wherein each cooling section is configured to be positioned adjacent to the battery module, wherein the inlet port is positioned closer to the first cooling loop compared to the second cooling loop, and the flow of cooling media at the cooling section closest to the inlet port is higher than the flow of cooling media in the cooling section closest to the outlet port.

According to some aspects, the second cooling loop is connected to the inlet port via the inlet manifold and connected to the outlet port via the outlet manifold, wherein the flow of cooling media in the cooling section closest to the first manifold is the same as the flow of cooling media in the cooling section closest to the second manifold.

According to some aspects, each transport section is configured to balance the flow of media between the first cooling loop and second cooling loop.

This disclosure further relates to an energy storage system comprising at least one system as disclosed above.

The description of the example embodiments provided herein have been presented for purposes of illustration. The description is not intended to be exhaustive or to limit example embodiments to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of various alternatives to the provided embodiments. The examples discussed herein were chosen and described in order to explain the principles and the nature of various example embodiments and its practical application to enable one skilled in the art to utilize the example embodiments in various manners and with various modifications as are suited to the particular use contemplated. The features of the embodiments described herein may be combined in all possible combinations of apparatus, modules and systems. It should be appreciated that the example embodiments presented herein may be practiced in any combination with each other.

It should be noted that the word “comprising” does not necessarily exclude the presence of other elements or steps than those listed and the words “a” or “an” preceding an element do not exclude the presence of a plurality of such elements. It should further be noted that any reference signs do not limit the scope of the claims, and that several “means”, “units” or “devices” may be represented by the same item of hardware.

In the drawings and specification, there have been disclosed exemplary embodiments. However, many variations and modifications can be made to these embodiments. Accordingly, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the embodiments being defined by the following claims.