Battery pack directed venting system

• US 8,557,416 B2
• Filed: 05/19/2012
• Issued: 10/15/2013
• Est. Priority Date: 04/22/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Mardall, Joseph, Herron, Nicholas Hayden, Grace, Dustin, Hermann, Weston Arthur, Weintraub, Jeffrey C., Pinkley, Gary Allen
• Primary Examiner(s): DOUYETTE, KENNETH J
• Application Number:
  US13/475,966
• Publication Number:
  US 20120237803A1
• Time in Patent Office: 514 Days
• Field of Search: 429/53, 429/82, 429/163, 429/185, 429/54, 429/56, 429/57, 429/148, 320/147, 180/65.1
• US Class Current: 429/53
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/653 characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/655 Solid structures for heat exchange or heat conduction
• CPC Class Codes: H01M 10/6556 Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 10/658 by thermal insulation or shielding
• CPC Class Codes: H01M 2200/10 Temperature sensitive devices
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/262 with fastening means, e.g. locks
• CPC Class Codes: H01M 50/342 Non-re-sealable arrangements
• CPC Class Codes: H01M 50/358 External gas exhaust passages located on the battery cover or case
• CPC Class Codes: H01M 50/367 : Internal gas exhaust passages forming part of the battery cover or case; Double cover vent systems
• CPC Class Codes: H01M 50/383 : Flame arresting or ignition-preventing means
• CPC Class Codes: H01M 50/394 : Gas-pervious parts or elements
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries

Abstract

A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack, the system using an integrated battery venting assembly comprised of an integrated exhaust port, a valve retention plate that covers the exhaust port and includes a plurality of retention plate ports, and a plurality of valves that are configured to seal the retention plate ports under normal conditions and unseal the retention plate ports during thermal runaway. As hot gas passes through the retention plate ports, the plate is configured to melt and be ejected, thereby allowing subsequent hot gas to pass through the larger exhaust port. A perforated cover plate may be used to protect the external surfaces of the retention plate and valves. An internally mounted exhaust guide may be used to direct the flow of hot gas expelled during the thermal runaway event.

Claims

1. A battery pack thermal management system, comprising:

a sealed battery pack enclosure configured to hold a plurality of batteries; and

a battery venting assembly integrated into said sealed battery pack enclosure, wherein said battery venting assembly is comprised of;

an exhaust port integrated into an outer wall of said sealed battery pack enclosure;

a valve retention plate coupled to a surface of said outer wall of said sealed battery pack enclosure, wherein said valve retention plate covers said exhaust port, and wherein said valve retention plate is comprised of a plurality of retention plate ports; and

a plurality of valves configured to seal said plurality of retention plate ports, wherein each of said plurality of valves seals said corresponding retention plate port under normal operating conditions and unseals said corresponding retention plate port when an excess pressure arises within said sealed battery pack enclosure, said excess pressure due to one or more of said plurality of batteries entering into thermal runaway,

wherein a first portion of each valve of said plurality of valves is comprised of a retention plate port sealing member, and wherein a second portion of each valve of said plurality of valves is comprised of a retention member configured to be captured within a retention aperture corresponding to each retention plate port.

2. The battery pack thermal management system of claim 1, wherein said sealed battery pack enclosure is divided into a plurality of sealed battery pack compartments, wherein said plurality of batteries are divided among said plurality of sealed battery pack compartments, and wherein said battery venting assembly is integrated into one of said plurality of sealed battery pack compartments.

3. The battery pack thermal management system of claim 2, said sealed battery pack enclosure further comprising a central battery pack member and a plurality of cross-members integrated within said sealed battery pack enclosure, wherein said central battery pack member and said plurality of cross-members divide said sealed battery pack enclosure into said plurality of sealed battery pack compartments, and wherein said central battery pack member and each of said plurality of cross-members presents a thermal barrier to the transfer of thermal energy between said sealed battery pack compartments.

4. The battery pack thermal management system of claim 1, wherein said valve retention plate is configured to unseal said exhaust port of said sealed battery pack enclosure as hot gas passes through said plurality of retention plate ports during said thermal runaway of one or more of said plurality of batteries.

5. The battery pack thermal management system of claim 4, wherein said valve retention plate is fabricated from a plastic material, and wherein said valve retention plate melts and is ejected from said exhaust port of said sealed battery pack enclosure as hot gas passes through said plurality of retention plate ports during said thermal runaway of one or more of said plurality of batteries.

6. The battery pack thermal management system of claim 5, further comprising a valve cover plate fabricated from a plastic material and coupled to an external surface of said outer wall of said sealed battery pack enclosure, wherein said valve retention plate is coupled to an internal surface of said outer wall of said sealed battery pack enclosure, wherein said valve cover plate shields an external surface of said valve retention plate and an external surface of each of said plurality of valves, wherein said valve cover plate is comprised of a plurality of openings, and wherein said valve cover plate melts and is ejected as hot gas passes through said plurality of retention plate ports during said thermal runaway of one or more of said plurality of batteries.

7. The battery pack thermal management system of claim 1, further comprising a valve cover plate coupled to an external surface of said outer wall of said sealed battery pack enclosure, wherein said valve retention plate is coupled to an internal surface of said outer wall of said sealed battery pack enclosure, wherein said valve cover plate shields an external surface of said valve retention plate and an external surface of each of said plurality of valves, and wherein said valve cover plate is comprised of a plurality of openings.

8. The battery pack thermal management system of claim 7, further comprising a plurality of bolts attaching said valve cover plate to said valve retention plate, wherein a region of said outer wall encircling said exhaust port is captured between a rim of said valve cover plate and a rim of said valve retention plate when said valve cover plate is attached to said valve retention plate with said plurality of bolts.

9. The battery pack thermal management system of claim 7, said plurality of openings comprised of a plurality of cover plate perforations.

10. The battery pack thermal management system of claim 1, wherein said first portion of each valve of said plurality of valves is umbrella shaped and wherein said second portion of each valve of said plurality of valves is further comprised of a barbed member configured to be captured within said retention aperture corresponding to each retention plate port.

11. The battery pack thermal management system of claim 1, wherein each valve of said plurality of valves is fabricated from an elastomeric material.

12. The battery pack thermal management system of claim 11, wherein said elastomeric material is comprised of a fluorosilicone.

13. The battery pack thermal management system of claim 1, further comprising a ducted exhaust guide, wherein said ducted exhaust guide is mounted within said sealed battery pack enclosure, wherein said ducted exhaust guide surrounds and is spaced apart from at least a portion of an inside surface of said valve retention plate, and wherein said ducted exhaust guide is configured to direct hot gas and material expelled from within said sealed battery pack enclosure through said plurality of retention plate ports to an ambient environment during thermal runaway.

14. The battery pack thermal management system of claim 13, wherein said ducted exhaust guide is configured to direct said hot gas and material expelled from within said sealed battery pack enclosure in a forward direction away from a vehicle centerline during thermal runaway, wherein said vehicle centerline corresponds to a vehicle, and wherein said sealed battery pack enclosure is incorporated into said vehicle.

15. The battery pack thermal management system of claim 13, wherein at least a portion of said ducted exhaust guide is angled away from an inside surface of said outer wall of said sealed battery pack enclosure at an angle of between 10 and 40 degrees.

16. The battery pack thermal management system of claim 15, wherein said angle is between 15 and 30 degrees.

17. The battery pack thermal management system of claim 13, wherein said ducted exhaust guide is fabricated from a material selected from the group of materials consisting of aluminum, aluminum alloys and steel.

18. The battery pack thermal management system of claim 1, wherein each valve of said plurality of valves has a cracking pressure in the range of 0.5 to 1.0 psi.

19. The battery pack thermal management system of claim 1, said sealed battery pack enclosure further comprising at least one two-way pressure equalization valve, wherein said two-way pressure equalization valve has a first cracking pressure and each valve of said plurality of valves has a second cracking pressure, wherein said first cracking pressure is less than said second cracking pressure.