DESC:
FIELD
The present disclosure relates to a battery pack assembly, and more specifically, relates to an arrangement for venting gas from a battery pack assembly.
DEFINITION
Vent gas: – The term ‘vent gas’ relates to a mixture of combustible gases discharged by a battery during thermal runway, i.e., when the heat generated by the battery exceeds the amount of heat it can dissipate.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Thermal runaway propagation caused due to vent gas dissipated within a battery pack assembly poses a substantial safety threat to the assembly, as malfunctioning of even a single battery cell can result in an uncontrolled discharge of heat, thereby triggering subsequent reactions which can lead to undesired thermal events. It is therefore imperative to shield and isolate the electronic and electrical (E&E) components within the battery pack assembly to ensure that any thermal propagation remains confined to the designated venting pathway, preventing its uncontrolled diffusion and achieving a state of complete thermal containment. However, it has been observed that the traditional methodology of gas venting inadvertently allows some quantity of vented gas to infiltrate in the electronic components, thereby leading to short-circuiting or explosion of various connected elements and electronic components of the assembly.
Therefore there is felt a need for an arrangement for venting gas from a battery pack assembly that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide an arrangement for venting gas from a battery pack assembly.
Another object of the present disclosure is to provide an arrangement for venting gas from a battery pack assembly which can offer a compact assembly.
Still another object of the present disclosure is to provide an arrangement for venting gas from a battery pack assembly which can efficiently route vent gas towards the venting valve.
Yet another object of the present disclosure is to provide an arrangement for venting gas from a battery pack assembly which can isolate vent gas from the electronic components.
Still another object of the present disclosure is to provide an arrangement for venting gas from a battery pack assembly which can efficiently guide vent gas from one battery module to the adjacent battery module.
Yet another object of the present disclosure is to provide an arrangement for venting gas from a battery pack assembly which does not require separate insulation for protecting the electronic components of the battery pack.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages an arrangement for venting gas from a battery pack assembly. The arrangement comprises a battery pack frame defined by side walls and a base. The frame has a pair of vent holes configured on an operative rear side wall of the frame. A plurality of longitudinal members is arranged in the frame along an operative longitudinal axis of the frame at a predetermined spaced-apart distance from each other. A plurality of cross members is arranged in the frame across the longitudinal members at a predetermined spaced-apart distance from each other to define a plurality of recesses between the longitudinal members and the cross members.
The arrangement further comprises a plurality of battery modules. Each battery module, containing a plurality of cells, is configured to be received in a recess. Each cell has at least one vent configured thereon for releasing vent gas discharged by the cell.
An insulating sheet is configured to be disposed between the base and the battery modules. The insulating sheet has a plurality of slits configured thereon. The slits are configured to fluidly communicate with the vents and the vent holes to facilitate release of vent gas from the vents to the vent holes.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
An arrangement for venting gas from a battery pack assembly, of the present disclosure will now be described with the help of the accompanying drawing in which:
Figure 1 illustrates an isometric view of a cell of the arrangement of the present disclosure;
Figure 2 illustrates a side view of a battery module of the arrangement of the present disclosure;
Figure 3a illustrates a top view of a battery pack of the arrangement of the present disclosure;
Figure 3b illustrates a bottom view of the battery pack of Figure 3a;
Figure 4a illustrate a cross-sectional view of the battery pack assembly of Figure 3b;
Figure 4b illustrates an enlarged sectional view of a battery module of Figure 4a;
Figure 5a illustrates a cross-sectional view of the battery pack assembly;
Figures 5b and 5c illustrate different sectional views of Figure 5a of the battery module and vent pathway of the battery frame;
Figure 6 illustrates a close-up view of a battery module, of Figure 5c, provided with a sealing at a bottom portion of the battery module;
Figure 7 illustrates a top view of the battery pack assembly with HV bus bars, battery modules and different electrical components;
Figure 8 illustrates an isometric view of the insulating sheet;
Figure 9 illustrates an isometric view of the battery frame with the cross member and the longitudinal member;
Figure 10 illustrates a top view of the arrangement showing the direction of flow of vent gas along the bottom portion of the battery pack assembly in accordance with an embodiment of the present disclosure;
Figures 11a-11d illustrate cross-sectional views of different cross members;
Figure 12 illustrates an isometric view of a rear member of the battery frame;
Figure 12a illustrates a close-up cross-sectional view of the rear member of Figure 12;
Figure 13a and Figure 13b illustrates different views of the venting valve provided on the rear frame of the battery frame;
Figure 14 illustrates a top view of the frame with different sections of the passage defined therein; and
Figures 15a-15e illustrate different views of the arrangement of the present disclosure.
LIST OF REFERENCE NUMERALS
100 Arrangement for venting gas from a battery pack assembly
02 Frame
05 Base
07 Recess
10 Cell
12 Vent
14 Battery module
16 Venting valve
18 Flange
20 Cross member
24 Longitudinal member
26 Insulating sheet
28 Cavity of the cross member
30 Side member LH/RH
30A Rear side wall
34 Reinforcement member
36 HV busbars
38 Electronic components
40 Gas flow direction
42 Bottom portion with reinforcement of the battery pack
44 Vent passage
46 Channeling means
47 Slit
48 Tray for mounting electronic components
50a Upright configuration of the venting valve
50b Inverted configuration of the venting valve
52 Venting chamber
54 Rear member
L Longitudinal axis
DETAILED DESCRIPTION
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof. Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Thermal runaway propagation caused due to vent gas dissipated within a battery pack assembly poses a substantial safety threat to the assembly, as malfunctioning of even a single battery cell (10) can result in an uncontrolled discharge of heat, thereby triggering subsequent reactions which can lead to undesired thermal events. It is therefore imperative to shield and isolate the electronic and electrical (E&E) components within the battery pack assembly to ensure that any thermal propagation remains confined to the designated venting pathway, preventing its uncontrolled diffusion and achieving a state of complete thermal containment. However, it has been observed that the traditional methodology of gas venting inadvertently permits some quantity of vented gas to infiltrate in the electronic components, thereby leading to short-circuiting or explosion of various connected elements and electronic components of the assembly. Therefore, there is felt a need for an arrangement for venting gas from a battery pack assembly and alleviating the aforementioned drawbacks.
The present disclosure envisages an arrangement (100) for venting gas from a battery pack assembly and describes it in detail with reference to Figures 1 through 15e. The arrangement (100) comprises a battery pack frame (02) defined by a plurality of side walls (30) and a base (05). The frame (02) has a pair of vent holes (not shown in figures) configured on an operative rear side wall (30A) of the frame (02). In an embodiment, the arrangement (100) includes a pair of venting valves (16) configured to be mounted on the pair of vent holes. The venting valves (16) are configured to release vent gas to the environment when the value of pressure of vent gas in battery pack assembly exceeds a predetermined pressure value. The frame (02) also has an opening configured on an operative front side wall thereof for mounting various electrical components (38) like BDU, BMS, CSC, etc. thereon.
A plurality of longitudinal members (24) is arranged in the frame along an operative longitudinal axis of the frame at a predetermined spaced-apart distance from each other. A plurality of cross members (20) is arranged in the frame across the longitudinal members (24) at a predetermined spaced-apart distance from each other to define a plurality of recesses (07) between the longitudinal members (24) and the cross members (20).
The arrangement (100) also comprises a plurality of battery modules (14) containing a plurality of cells (10). The battery modules (14) are configured to be received in a recess (07). As shown in Figure 1, each cell (10) has at least one vent (12) configured thereon for releasing vent gas discharged by the cell (10). In an embodiment, the cells (10) are stacked into the module to contain any thermal event. In another embodiment, a thermal barrier foam is placed between the cells (10).
The arrangement (100) further comprises an insulating sheet (26) configured to be disposed between the base (05) and said battery modules (14). The insulating sheet (26) has a plurality of slits (47) configured thereon. The slits (47) are configured to fluidly communicate with the vents (12) and the vent holes to facilitate release of vent gas from the vents (12) to the vent holes.
Figure 2 shows direction of air flow into a battery module (14) having a plurality of battery cells (10).
Figure 3a illustrates a top view of a battery pack assembly, while Figure 3b illustrates a bottom view of the battery pack assembly.
In one embodiment, the vent (12) is configured on an operative bottom surface of the battery cell (10). Figure 8 shows placement of the battery modules (14) in the battery pack that allows the vent (12) of the cell (10) to face the base (05), with the insulating sheet (26) disposed between the frame (02) and the battery module (14). In another embodiment, the battery modules (14) are configured to be disposed on the insulating sheet (26) such that the vents (12) are positioned above the slits (47).
In a further embodiment, the frame (02) includes a plurality of flanges (18) configured to extend from an operative top surface of the side walls (30), the longitudinal members (24) and the cross members (20). In an embodiment, the flanges (18) are configured to extend along the length of the battery pack frame (02). The flanges (18) are configured to facilitate secure installation of the battery modules in the recesses. In an embodiment, the insulating sheet (26) is of mica.
In another embodiment, the insulating sheet (26) is disposed on the base at a spaced apart distance from the base (02) to define a gap therebetween. The gap is configured to facilitate passage of vent gas received from the slits (47) of the insulating sheet (26) towards the vent holes.
In another embodiment, a plurality of cavities (28) is configured at predetermined locations on each cross member (20). The cavities (28) are configured to receive vent gas discharged by the cells (10), and are further configured to facilitate flow of vent gas towards the venting valves (16) of the battery frame.
Figure 4a illustrates a cross-sectional view of the battery pack assembly. Figure 4b illustrates a close-up view of the battery modules (14) with the cavities (28) provided on the operative bottom portion of the battery frame for venting vent gas therethrough. The frame is configured such that a vent passage (44) is defined at specific points marked as a1, a2, a3, b1, and b3 that interconnects different modules; while at points c1, b2, and c2 locations, this pathway is obstructed, thereby effectively confining the vented gases to the area between c1, b2, and c2. The obstructions help prevent dispersion of vent gas towards the portion of the battery frame (02) comprising the electronic components.
On the other hand, the cavities (28) are uniformly configured on the cross-members (20). More specifically, at section B-B, the cross members (20) allow venting of the vent gas at b1 and b3, while at b2, they are configured to block passage of vent gases towards the electronic and electrical (E&E) components. Further, at section C-C, the cross members (20) are configured to prevent flow of vent gas towards the E&E components by blocking at c1 and c2 positions.
Figure 4a illustrates a top view of the frame (02) with cavities (28) configured thereon for passage of vent gas therethrough. Figure 4b illustrates a sectional view of the battery pack assembly in which only one side cross member (20) is shown with the cavity (28). In an embodiment, the cross member (20) in an operative middle portion of the frame (02) does not have any cavity (28) configured thereon, and therefore can restrict the flow of vent gas towards the electrical components.
In an embodiment, the battery frame (02) is configured to seal the battery modules (14) from all operative sides to ensure the venting of gas is channelized through the venting valves (16). In one embodiment, the arrangement (100) includes a plurality of reinforcement members (34) provided at an operative bottom surface of the battery modules (14). The reinforcement members (34) are configured to prevent passage of vent gas towards an operative front portion of the frame.
In another embodiment, the arrangement (100) includes a plurality of gaskets (not shown in figures) provided at an operative bottom surface of the modules. The gaskets are configured to prevent passage of vent gas towards an operative front portion of the frame (02).
In one embodiment, the arrangement (100) includes a sealing provided along an operative top periphery of the battery modules. The sealing is configured to ensure that there is no flow of vent gas through the top portion of the battery module (14). Advantageously, both channelization of vent gas through the venting valves (16) and sealing all around the battery modules (14) (at bottom, and front of the module (14)) ensure that vent gas does not escape to the top of the battery module (14), thereby ensuring zero thermal propagation especially in the tray space (48) of the battery pack assembly with respect to HV & LV components (BDU, BMS, CSC, Header unit, HV busbars (36), LV harness, etc.,).
Figure 13A illustrates a cross-sectional view of the frame (02) with a venting valve (50a) provided thereon with respect to top placement of the battery pack. Figure 13B illustrates a cross-sectional view of the frame with respect to bottom placement of the battery pack. In Figure 14, an alternative configuration of the frame assembly is illustrated showing the concept of mounting the arrangement (100) at a vehicular level. This configuration is adaptable for a wide range of vehicle level mountings, including both top and bottom placements of the battery pack, as depicted in figure 13a and figure 13b. Consequently, channeling passages (44) are optimized and the positioning of venting valves (16) can be adjusted accordingly. This proposal serves as a universal solution, applicable to the installation of venting valves (16) on any member of the pack—be it front, rear, left-hand (LH), or right-hand (RH)—using this distinct configuration. In an embodiment, the corresponding sealing arrangement can be optimized to match the desired configuration. In a further embodiment, the configuration is scalable from a single vent valve to multiple venting valves based on specific venting requirements. The application of the arrangement of the present invention can be extended to any of the side members (Front/Rear/LH/RH) (30) and can be adapted to facilitate venting in various directions: top direction, bottom direction, front direction, rear direction, LH direction, or RH direction, as illustrated above.
Depending on the cell venting position and the position of the terminals, the modules (14), the frame (02), the cooling plate and the bottom cover of the battery assembly are configured so that in an event of thermal runaway, the vent gas is contained in the assembly, and does not escape into the other internal components of battery pack, nor does it enter the passenger compartment of a vehicle.
Figure 7 shows the battery pack architecture of module, E&E components design and layout within frame assembly. Battery modules (14) are mounted on the frame, while module to module High Voltage (HV) Busbars (36) are connected using copper/aluminum busbars, a Battery Disconnect Unit (BDU), a Battery Management System (BMS) and a Cell Monitoring Circuit (CMC) are placed over the frame assembly, and a Header unit (HV/LV connector) is mounted from front and wiring harness is placed in between the busbars.
Figure 15a-15e illustrates different views of a bottom cover reinforcement for the battery pack assembly. Figure 15a illustrates an alternative configuration for bottom cover reinforcement, specifically focusing on aspects related to sealing and venting. The bottom portion of the frame, as shown in Figure 15a, highlights a configuration where the venting is accommodated within the cross member (20), and the bottom cover reinforcement is levelled and sealed using a gasket. As showcased in figure 15a, the top portion of the frame (02) features a flat cross member (20), while the reinforcement provided at the bottom cover is configured to cater to both sealing and venting needs. Furthermore, these two distinct configurations can be synergistically employed, as demonstrated in Figures 15b-15e. This selection depends on the specific sectional area requirements for vent gas flow. In this combined approach, both the cross member (20) and the reinforcement possess features that facilitate venting.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, the arrangement for venting gas from a battery pack assembly, that;
• can effectively seal the tray space (for mounting the electronics component such as BMS, BDU, CSC) from high temperature vent gas;
• can effectively route vent gas from the battery module towards the rear part of the battery frame to get release from the venting valve; and
• effectively seal the cross member and the longitudinal member to avoid leakage of vent age in the tray space.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:

1. An arrangement (100) for venting gas from a battery pack assembly, said arrangement (100) comprising:
• a battery pack frame (02) defined by side walls (30) and a base (05), said frame (02) having a pair of vent holes (not shown in figures) configured on an operative rear side wall (30A) of said frame (02);
• a plurality of longitudinal members (24) arranged in said frame (02) along an operative longitudinal axis (L) of said frame (02) at a predetermined spaced-apart distance from each other;
• a plurality of cross members (20) arranged in said frame across said longitudinal members (24) at a predetermined spaced-apart distance from each other to define a plurality of recesses (07) between said longitudinal members (24) and said cross members (20);
• a plurality of battery modules (14), each battery module (14) containing a plurality of cells (10), being configured to be received in a recess (07), each cell (10) having at least one vent (12) configured thereon for releasing vent gas discharged by said cell (10); and
• an insulating sheet (26) configured to be disposed between said base (05) and said battery modules (14), said insulating sheet (26) having a plurality of slits (47) configured thereon, said slits (47) configured to fluidly communicate with said vents (12) and said vent holes to facilitate release of vent gas from said vents (12) to said vent holes.
2. The arrangement (100) as claimed in claim 1, which includes a pair of venting valves (16) configured to be mounted on said pair of vent holes, said venting holes configured to release vent gas to the environment when the value of pressure of vent gas in battery pack assembly exceeds a predetermined pressure value.
3. The arrangement (100) as claimed in claim 1, wherein a plurality of cavities (28) is configured at predetermined locations on each cross member (20), said cavities (28) configured to receive vent gas discharged by said cells (10), and further configured to facilitate flow of vent gas towards the venting valves (16) of the battery frame.
4. The arrangement (100) as claimed in claim 1, wherein said vent (12) is configured on an operative bottom surface of said battery cell (10).
5. The arrangement (100) as claimed in claim 4, wherein said battery modules (14) are configured to be disposed on said insulating sheet (26), wherein said vents (12) are positioned above said slits (47).
6. The arrangement (100) as claimed in claim 1, wherein said frame (02) includes a plurality of flanges (18) configured to extend from an operative top surface of said side walls (30), said longitudinal members (24) and cross members (20), said flanges (18) being configured to facilitate secure installation of said battery modules (14) in said recesses (07).
7. The arrangement (100) as claimed in claim 1, wherein said insulating sheet (26) is disposed on said base (05) at a spaced apart distance to define a gap therebetween to facilitate passage of vent gas received from said slits (47) of said insulating sheet (26) towards said vent holes, said insulating sheet (26) being of mica.
8. The arrangement (100) as claimed in claim 1, which includes a plurality of reinforcement members (34) provided at said operative bottom surface of said modules (14), said reinforcement members (34) being configured to prevent passage of vent gas towards an operative front portion of said frame (02).
9. The arrangement (100) as claimed in claim 1, which includes a plurality of gaskets (not shown in figures) provided at said operative bottom surface of said modules (14), said gaskets being configured to prevent passage of vent gas towards an operative front portion of said frame (02).

10. The arrangement (100) as claimed in claim 1, which includes a sealing (not shown in figures) provided to along an operative top periphery of the battery modules (14) to ensure that there is no flow of vent gas through the top portion thereof.

Dated this 06th day of July, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, MUMBAI