RELATED APPLICATION INFORMATION

This application claims the benefit of U.S. Provisional Application No. 63/201,053, filed April 4, 2021, the contents of which are fully incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to the coolant batteries electric vehicles, and more particularly to devices, systems and methods of coolant batteries through the use of one or more extruded planks defining a conduit through which a coolant can pass.

BACKGROUND

Electric vehicles are becoming increasingly popular as consumers look to decrease their environmental impact and improve air quality. Instead of a traditional internal combustion engine (ICE), electric vehicles include one or more motors, powered by a rechargeable battery pack. A common battery pack is made up of one or more battery modules, each module containing a plurality of battery cells, which act as galvanic cells when being discharged by converting chemical energy to electrical energy, and electrolytic cells when being recharged by converting electrical energy to chemical energy. As is well known, these battery cells can generate heat in use during discharge and recharge. In rare circumstances, where the heat becomes excessive, the battery can ignite and bum, which can result in damage to the vehicle or even potential harm the occupants.

To manage heat generation, heat exchangers are often incorporated into the vehicle structure. Some heat exchangers use the frame of the battery pack to cool the battery cells, such as that as seen in US9496589B2. Other heat exchangers use heating or cooling tubes located between the battery cells, such as that seen in US9113577B2. Yet other heat exchangers include cooling plates sandwiched between the battery pack and platform to which it is mounted, such as that depicted in FIG. 1. Although cooling plates such as that depicted in FIG. 1 are generally effective in providing cooling for the battery, such cooling plates and unwanted mass and bulk to the body of the vehicle. The present disclosure addresses this concern. SUMMARY OF THE DISCLOSURE

Embodiments of the present disclosure provide a vehicle battery cooling device, and system and method including one or more battery cooling blocks onto which one or more battery modules can be mounted, the battery cooling blocks including a plurality of extrusions thereby defining conduits through which a temperature regulation fluid can flow, to provide a more compact, lighter weight solution in which battery temperature regulation can be accomplished without the unwanted mass and bulk normally associated with conventional cooling plates.

In some embodiments, the battery cooling blocks can include one or more flow diverters within individual extrusions configured to guide the temperature regulation fluid through a serpentine pattern or other patterns to adjust the residence time of the temperature regulation fluid in proximity to the one or more battery modules. In some embodiments, the flow diverters can be adjusted to increase or decrease the residence time of the temperature regulation fluid, thereby enabling thermal regulation adjustment. In other embodiments, the extrusions are in fluid communication with each other, thereby defining a serpentine pattern or other patterns to adjust the residence time of the temperature regulation fluid in proximity to the one or more battery modules. In yet other embodiments, the battery cooling block includes a combination of flow diverters within each extrusion and along the extrusions.

One embodiment of the present disclosure provides an electric vehicle battery cooling block, including a rigid plate including a plurality of walls defining one or more temperature regulation fluid conduits in a serpentine pattern, the rigid plate configured to structurally support a rechargeable battery assembly for an electric vehicle, as well as to act as one or more structural members of the electric vehicle.

In one embodiment, a first surface of the rigid plate is configured to contact the rechargeable battery assembly and a second surface of the rigid plate is configured to serve as an exterior of the electric vehicle. In one embodiment, the rigid plate is at least partially constructed of an extruded material. In one embodiment, the rigid plate is at least partially constructed of aluminum alloy. In one embodiment, the plurality of walls traverse across a y-axis of the electric vehicle. In one embodiment, the plurality of walls traverse across an x-axis of the electric vehicle.

In one embodiment, the rigid plate further includes one or more flow diverters configured to optimize a residence time of a temperature regulation fluid flowing through the one or more temperature regulation fluid conduits. In one embodiment, the rigid plate further includes at least one temperature regulation fluid conduit inlet and at least one temperature regulation fluid conduit outlet. In one embodiment, the at least one temperature regulation fluid conduit inlet and at least one temperature regulation fluid conduit outlet are positioned on opposite ends of the rigid plate. In one embodiment, the at least one temperature regulation fluid conduit inlet and at least one temperature regulation fluid conduit outlet are positioned on at a first end of the rigid plate.

Another embodiment of the present disclosure provides an electric vehicle, including a rechargeable battery assembly, and a rigid plate including a plurality of walls defining one or more temperature regulation fluid conduits in a serpentine pattern, the rigid plate configured to structurally support the rechargeable battery assembly for an electric vehicle, as well as to act as one or more structural members of the electric vehicle.

In one embodiment, a first surface of the rigid plate is configured to contact the rechargeable battery assembly and a second surface of the rigid plate is configured to serve as an exterior of the electric vehicle. In one embodiment, the rigid plate is at least partially constructed of an extruded material. In one embodiment, the rigid plate is at least partially constructed of aluminum alloy. In one embodiment, the rigid plate further includes one or more flow diverters configured to optimize a residence time of a temperature regulation fluid flowing through the one or more temperature regulation fluid conduits.

The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which: FIG. 1 is a cross-sectional view depicting a vehicle battery pack cooled via a pair of conventional cooling plates, in accordance with the prior art.

FIG. 2 is a cross-sectional view depicting a pair of battery modules cooled via temperature regulation fluid running through the conduit defined in an extruded battery cooling blocks, in accordance with an embodiment of the disclosure.

FIG. 3 is a cross-sectional view of an extruded battery cooling block having one or more cooling channels, wherein the one or more cooling channels are longitudinally oriented with respect to one or more battery modules positioned atop of the extruded battery cooling block, in accordance with an embodiment of the disclosure.

FIG. 4 is a cross-sectional view of a extruded battery cooling block having one or more cooling channels, wherein the one or more cooling channels are longitudinally oriented with respect to one or more battery modules positioned atop of the extruded battery cooling block, in accordance with a second embodiment of the disclosure.

FIG. 5 is a cross-sectional view of a extruded battery cooling block having a coolant inlet, a coolant outlet, and a serpentine coolant channel, in accordance with a third embodiment of the disclosure.

FIG. 6 is a cross-sectional view of a extruded battery cooling block having a coolant inlet, a coolant outlet, and a serpentine coolant channel, in accordance with a fourth embodiment of the disclosure.

FIG. 7 is a cross-sectional view of a extruded battery cooling block having a coolant inlet, a coolant outlet, and a serpentine coolant channel, in which the coolant inlet and coolant outlet are positioned on the same edge of the extruded battery cooling block, in accordance with a fifth embodiment of the disclosure.

FIG. 8 is a cross-sectional view of a extruded battery cooling block having a coolant inlet, a coolant outlet, and a serpentine coolant channel, in which the coolant channels are laterally oriented with respect to one or more batteries positioned atop of the extruded battery cooling block in accordance with a sixth embodiment of the disclosure.

FIG. 9 is a cross-sectional view of a extruded battery cooling block having a coolant inlet, a coolant outlet, and a serpentine coolant channel, in which the coolant channels are laterally oriented with respect to one or more batteries positioned atop of the battery cooling block, and the coolant inlet and coolant outlet are positioned on the same edge of the battery cooling block, in accordance with a seventh embodiment of the disclosure.

FIG. 10 is a cross-sectional view of a extruded battery cooling block having a coolant inlet, a coolant outlet, and a serpentine coolant channel, in which the coolant channels are both longitudinally and laterally oriented with respect to one or more batteries positioned atop of the battery cooling block, and the coolant inlet and coolant outlet are positioned on the same edge of the battery cooling block, in accordance with a seventh embodiment of the disclosure.

FIG. 11 is a perspective view depicting a motor vehicle including an extruded battery cooling block on which a plurality of battery modules are mounted, in accordance with an embodiment of the disclosure.

While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

Referring to FIG. 1, a cross-sectional view of a conventional cooling plate 50 sandwiched between a pair of battery modules 52A/B and a vehicle frame 54 (or other platform to which the cooling plate is mounted) is depicted in accordance with the prior art. Although the conventional cooling plate 50 has been found to be generally effective in providing temperature regulation to the battery modules 52A/B, the cooling plate 50 adds a significant amount of unwanted mass and bulk to the vehicle, which negatively affects performance (e.g., hinders 0-60 mph acceleration time and 60-0 mph braking distance), as well as decreasing the effective range of the vehicle.

Referring to FIG. 2, a cross-sectional view of a lighter weight, less bulky extruded temperature cooling block 100 configured to serve as both a vehicle battery temperature regulation mechanism and a platform onto which the battery modules 102A/B can be mounted, is depicted in accordance with an embodiment of the disclosure. As depicted, in some embodiments, the extruded temperature cooling block 100 can be a rigid structure sufficient to provide support to the plurality of battery modules 102A/B, and in some cases can serve as a portion of the vehicle frame and/or skin of the vehicle. For example, in some embodiments, the extruded temperature cooling block 100 can serve as both a rechargeable battery assembly tray and underside of the vehicle. In some embodiments, cooling block 100 can be constructed of an aluminum alloy material, although the use of other materials for the construction, such as galvanized stainless steel or reinforced or composite polymers, of the extruded battery cooling block is also contemplated.

Referring to FIGS. 3-4, cross-sectional views of an extruded battery cooling block 100 defining one or more cooling conduits or channels 104 through which a temperature regulation fluid can selectively flow is depicted in accordance with an embodiment of the disclosure. For example, as depicted, in one embodiment, the extruded battery cooling block 100 can include a plurality of cooling channels 104 can be generally longitudinally oriented with respect to one or more battery modules 102 positioned atop of the extruded battery cooling block 100. In some embodiments, the plurality of cooling channels 104 can be oriented to traverse laterally across the width (e.g., along the y-axis) of a motor vehicle. In other embodiments, the plurality of cooling channels 104 can be laterally oriented with respect to the one or more battery modules 102, for example to traverse longitudinally along a length (e.g., along the x-axis) of a motor vehicle. Other orientations that the cooling channels 104 are also contemplated.

As depicted in FIG. 3, a temperature regulation fluid F can be introduced in each of channels 104 at a first same end 105, and outputted from channels 104 at a second same end 107. The fluid can be provided from a single source in which it is simultaneously introduced in each of channels 104, or can be independently introduced from separate sources in each of channels 104. Likewise, the output can be collected from channels 104 as a single stream, or can be independently collected.

As depicted in FIG. 4, in alternative embodiments, flow can be directed into some of channels 104 at first end 105, while into some of other channels 104 at a second end 107, such as in an alternating pattern as shown, or in any combination as contemplated by one of ordinary skill in the art. In any of these embodiments, fluid flow can be reversed as desired.

Referring to FIGS. 5-7, in some embodiments, the extruded battery cooling block 100 can define one or more flow diverters 106A-D configured to route the temperature regulation fluid along a serpentine pattern 108. For example, in one embodiment, extended battery cooling block 100 can include a plurality of walls 110 defining the cooling channels 104, wherein portions of the walls 110 are removed to define one or more flow diverters 106A-D. In embodiments, in addition to defining the cooling channels 104, the plurality of walls 110 can provide structural support to the extruded battery cooling block 100 sufficient to both support the weight of the rechargeable battery assembly, as well as to act as one or more structural/frame members of the motor vehicle. In some embodiments, the serpentine pattern 108 and/or flow diverters 106 can be configured to optimize a residence time of temperature regulation fluid flowing through the extruded battery cooling block 100.

A first end 112 and a second end 114 of the extruded battery cooling block can be respectively sealed with first wall 116 and a second wall 118, thereby defining a serpentine pattern 108 within the extruded battery cooling block 100. Specifically, in some embodiments, the one or more cooling channels 104 of an extruded battery: block 100 can be at least partially sealed by first wall 116 and second wall 118 (e.g., by welding or otherwise affixing first wall 116 and second wall 118 to the extruded element 100). In some embodiments, portions of the extruded element can be machined to remove material, thereby defining a serpentine pattern 108 within the extruded battery cooling block 100. An inlet 120 and an outlet 122 can be defined within the walls 116, 118 of the extruded battery cooling block 100. For example, as depicted in FIGS. 5-6, in some embodiments, the respective inlet 120 and outlet 122 can be positioned on opposing ends 112, 114 of the extruded battery cooling block 100. In other embodiments, such as that depicted in FIG. 7, the inlet 120 and outlet 122 can be located on the same end (e.g., first end 112).

With reference to FIGS. 8-9, one or more sidewalls 110 are formed within individual extrusions 101 to define one or more flow diverters 106A-106C such that flow is diverted into a serpentine path 108 within extrusion 101 itself. Sidewalls 110 can extend an entirety of the height of extrusion 101, or only a portion thereof thereby forming baffles. In an embodiment depicted in FIG. 8, the respective inlet 120 and outlet 122 can be positioned on opposing ends 112, 114 of extrusion 101. In other embodiments, such as that depicted in FIG. 9, inlet 120 and outlet 122 can be located on the same end (e.g., first end 112).

In some embodiments, and as shown in FIGS. 8 and 9, sidewalls 110 can traverse along a width (e.g., along the y-axis) of the vehicle, while in other embodiments (not shown), sidewalls 110 can extend a length (e.g., along the x-axis) of the vehicle. In yet other embodiments, the sidewalls can be both laterally and longitudinally oriented with respect to one or more battery modules positioned atop of the battery cooling block. For example, with reference to FIG. 10, a cross- sectional view of an extrusion 101 having a coolant inlet 120, a coolant outlet 122, and a serpentine coolant channel 108, includes sidewalls 110 that are both longitudinally and laterally oriented with respect to one or more batteries positioned atop of the battery cooling block, and the coolant inlet and coolant outlet are positioned on the same edge of the battery cooling block, in accordance with an embodiment of the disclosure. It is also contemplated that the plurality of extrusions can be configured in a similar arrangement, rather than or in addition to sidewalls within individual extrusions.

In some embodiments, it may be desired to form sidewalls within each individual extrusion while also configuring the plurality of extrusions to be fluidly coupled. For example, a plurality of extrusions 101 depicted in FIG. 8 may be arranged together as depicted in FIG. 5. In embodiments, fluid F can be any of a variety of temperature regulating fluids such as, for example, water, saline, cryogenic fluid, air, organic solvents such as ethylene glycol or propylene glycol, electrolytic solutions, or combinations thereof. Fluid F can be room temperature or pre-cooled. In other embodiments, in which it is desired to warm the battery before use in cold climates, fluid F can be warmed before flowing through the extrusions.

With reference to FIG. 11, a motor vehicle 130 including an extruded battery cooling block on which a plurality of battery modules 102 are mounted is depicted in accordance with an embodiment of the disclosure. In some embodiments, the extruded temperature cooling block 100 can be a rigid structure sufficient to both provide support to the plurality of battery modules 102, and can serve as a portion of the vehicle frame and/or skin of the vehicle. In embodiments, cooling plates may be added to the battery cooling block if additional cooling is required or desired.

Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.