The present application claims priority from Japanese Patent Application No. 2020-047614 filed on Mar. 18, 2020, the entire contents of which are hereby incorporated by reference.
The disclosure relates to a battery stack structure and, in particular, relates to a battery stack structure including a cooling mechanism.
In general, an onboard battery houses a lot of plate-shaped battery cells. Japanese Unexamined Patent Application Publication (JP-A) No. 2013-80625 discloses such type of onboard battery.
For example, a battery module disclosed in JP-A No. 2013-80625 includes multiple unit battery cells having external terminals that are mutually electrically coupled by a bus bar. The battery module also includes a heat transmission cover that covers the bus bar in direct contact with the bus bar. The heat transmission cover is an insulative heat conductive member and is in direct contact with a battery container of the unit battery cell. With this structure, heat that is generated in an electrode group is efficiently transmitted to a surface of the battery container in charging and discharging. Thus, the unit battery cell is effectively cooled, and the battery module can be reduced in dimensions.
JP-A No 2015-012628 discloses a cooling unit for cooling a battery cell and its peripheral device of an onboard battery. According to JP-A No. 2015-032628, an electronic component passage is formed in a junction box. The electronic component passage makes a battery cooling passage communicate with the outside of the junction box. With this structure, after air that flows into a battery case passes through the battery cooling passage to cool a battery, the air passes through the electronic component passage to cool an electronic component and is then discharged to the outside of the junction box.
An aspect of the disclosure provides a battery stack structure including a battery stack, a cooling air introduction passage, a junction box, and a bus bar. The battery stack includes multiple battery cells that are spaced from each other. The cooling air introduction passage is adjacent to a first side of the battery stack. The cooling air introduction passage is configured to allow air to flow in the cooling air introduction passage before the air cools the battery stack. The junction box is adjacent to a second side of the battery stack. The junction box is configured to allow the air to flow in the junction box after the air has cooled the battery stack. The junction box contains an electronic device. The bus bar is contained in the junction box. The bus bar is electrically and thermally coupled to the electronic device. The bus bar is configured to allow passing of current that is charged to or discharged from the battery stack. The direction of the flow of the air flowing from the battery stack into the junction box faces a major surface of the bus bar.
The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate an embodiment and, together with the specification, serve to explain the principles of the disclosure.
The cooling structure disclosed in JP-A No. 2015-012628 has a possibility of improvement from a point of view of efficiency of cooling the electronic component in the junction box. In the state in which this cooling efficiency is insufficient, an expensive electronic component having a large heat capacity is employed, causing increase in cost.
On the other hand, due to recent progress in reduction in dimensions of an onboard battery, a battery stack may be disposed in a small space in a vehicle or in a space where flowability of air is low, in some cases. This makes it more difficult to improve the cooling efficiency of the battery stack.
Measures against these issues include employing a high rated relay, increasing a cross sectional area of a bus bar to enhance cooling efficiency, and reducing output current based on a measured temperature value of a relay. However, these measures may cause another issue such as increase in dimensions of the whole battery pack or reduction in output from the battery pack.
It is desirable to provide a battery stack structure configured to effectively cool an electronic device in a junction box.
In the following, an embodiment of the disclosure is described in detail with reference to the accompanying drawings. Note that the following description is directed to an illustrative example of the disclosure and not to be construed as limiting to the disclosure. Factors including, without limitation, numerical values, shapes, materials, components, positions of the components, and how the components are coupled to each other are illustrative only and not to be construed as limiting to the disclosure. Further, elements in the following embodiment which are not recited in a most-generic independent claim of the disclosure are optional and may be provided on an as-needed basis, The drawings are schematic and are not intended to be drawn to scale. Throughout the present specification and the drawings, elements having substantially the same function and configuration are denoted with the same numerals to avoid any redundant description.
The vehicle 10 is, for example, an automobile or a train, and is mounted with the battery stack structure 15, which will be described later. The battery stack structure 15 is used for supplying power to various electric components, such as a motor. Examples of the vehicle 10 include an electrical vehicle (EV), a hybrid electrical vehicle (HEV), and a plug-in hybrid electrical vehicle (PHEV).
The vehicle 10 includes a vehicle body 11, the multiple battery stack structures 15, a driving motor (not illustrated), and tires (not illustrated). The battery stack structures 15 are disposed in a battery disposition region 12 that is specified in the vicinity of a bottom surface 13 of the vehicle 10. The driving motor is driven by power supplied from the battery stack structure 15. The tires rotate by a driving force of the driving motor.
The multiple battery stack structures 15, which will be described later, are disposed in matrix in the battery disposition region 12, The battery stack structure 15 has, for example, an approximately rectangular parallelepiped shape. The multiple battery stack structures 15, which are efficiently disposed in the battery disposition region 12, extends a continuous travel distance of the vehicle 10.
The following description uses each of an up-down direction, a front-back direction, and a right-left direction. The up-down direction is a direction of stacking a lower battery stack 201 and an upper battery stack 202 that constitute the battery stack 20. The front-back direction is a direction of stacking battery cells 203 that constitute the upper battery stack 202. The right left direction is a direction of disposing the cooling air introduction passage 21 and the junction box 23 to the battery stack 20. Each direction used in
The battery stack 20 is disposed at the center in the right-left direction of the battery stack structure 15 and includes the lower battery stack 201 and the upper battery stack 202.
The lower battery stack 201 includes multiple battery cells 203 that are spaced along the front-back direction. The battery cell 203 is a secondary battery, such as a nickel hydrogen battery or a lithium ion battery, and each of the battery cells 203 has an approximately plate shape. This embodiment is configured to allow air to flow in the spaces between the battery cells 203 from the left to the right, whereby the battery cells 203 are effectively cooled.
As in the case of the lower battery stack 201, the upper battery stack 202 also includes multiple battery cells 203.
The cooling air introduction passage 21 is disposed on the left of the battery stack 20, and air before cooling the battery stack 20 flows in the cooling air introduction passage 21. The cooling air introduction passage 21 includes a lower cooling air introduction passage 211 and an upper cooling air introduction passage 212. The lower cooling air introduction passage 211 is disposed on the left of the lower battery stack 201. The upper cooling air introduction passage 212 is disposed on the left of the upper battery stack 202. The cooling air introduction passage 21 may also be referred to as a “duct”.
The lower cooling air introduction passage 211 is an approximately box-shaped body that is made of synthetic resin and that has an approximately rectangular parallelpiped shape as a whole. The lower cooling air introduction passage 211 has a back opening on a back surface and has a right opening on a right side surface. The back opening and the right opening are not illustrated herein. Air is supplied from the outside and advances forward in the lower cooling air introduction passage 211 via the back opening of the lower cooling air introduction passage 211. Then, the air that enters the lower cooling air introduction passage 211 is introduced into the space between the battery cells 203, which constitute the lower battery stack 201, via the right opening.
As in the case of the lower cooling air introduction passage 211, the upper cooling air introduction passage 212 also has a back opening and a right opening, which are not illustrated herein. Air is supplied from the outside and advances forward in the upper cooling air introduction passage 212 via the back opening of the upper cooling air introduction passage 212. Then, the air that enters the upper cooling air introduction passage 212 is introduced into the space between the battery cells 203, which constitute the upper battery stack 202, via the right opening.
The junction box 23 is disposed on the right of the battery stack 20 and houses an electronic device 22 and a bus bar 24 that is electrically and thermally coupled to the electronic device 22. The electronic device 22 will be described later. Air after cooling the battery stack 20 flows in the junction box 23. The junction box 23 has a lower junction box 231 and an upper junction box 232 that are arranged in a stacked manner.
The lower junction box 231 has an opening on a left side surface and has an opening on a front side surface. Herein, the left opening is not illustrated, but the front opening 214 is illustrated. Air after cooling each of the battery cells 203 of the lower battery stack 201 enters the lower junction box 231 from the left opening of the lower junction box 231 and advances forward in the lower junction box 231 to be discharged to the outside from the opening 214. This allows the air to effectively cool a lower bus bar 241 and electronic devices 22 that are disposed in the lower junction box 231. The lower bus bar 241 and the electronic device 22 will be described later.
The upper junction box 232 also has a structure and a function that are similar to those of the lower junction box 231. That is, the upper junction box 232 has an opening on a left side surface and an opening on a front side surface. Herein, the left opening is riot illustrated, but the front opening 213 is illustrated. Air after cooling each of the battery cells 203 of the upper battery stack 202 enters the upper junction box 232 from the left opening of the upper junction box 232 and advances forward therein to be discharged to the outside from the opening 213. This allows the air to effectively cool an upper bus bar 242 and an electronic device 22 that are disposed in the upper junction box 232. The upper bus bar 242 and the electronic device 22 will be described later.
With reference to
The structure, such as the inside structure, or the upper junction box 232 is similar to that of the lower junction box 231. That is, the upper junction box 232 has the opening 213 that opens to the front and also has an opening 215 that opens to the left. In the upper junction box 232, the upper bus bar 242 having an approximately plate shape extending in the front-back direction is disposed. As illustrated in
As described above, the lower bus bar 241, which is coupled to the negative electrode of the battery stack 20, is contained in the lower junction box 231, whereas the upper bus bar 242, which is coupled to the positive electrode of the battery stack 20, is contained in the upper junction box 232. Thus, the lower bus bar 241 of the negative electrode and the upper bus bar 242 of the positive electrode are separated from each other. This enables presenting a short circuit between the lower bus bar 241 and the upper bus bar 242 when a collision accident of the vehicle 10 occurs. Moreover, as viewed from above the junction box 23, the lower bus bar 241 and the upper bus bar 242 can be disposed in an overlapping manner, whereby the area for disposing the bus bar 21 can be reduced.
As illustrated in
Air is introduced into the lower battery stack 201 from the lower cooling air introduction passage 211. Then, after cooling each of the battery cells 203 of the lower battery stack 201, the air is introduced into the lower junction box 231. The temperature of the air after cooling the battery cells 203 of the lower battery stack 201 is, for example, in a range of 40 to 50° C. On the other hand, the temperature of the lower bus bar 241 that is heated by passing current from the battery stack 20, is for example, approximately 70° C. In these conditions, the air after cooling the lower battery stack 201 exchanges heat with the lower bus bar 241. This effectively cools the lower bus bar 241, and the fuse 221 (see
In this embodiment, the direction of the flow of air that flows from the lower battery stack 201 into the lower junction box 231, faces the major surface of the lower bus bar 241. In more detail, after cooling the battery cells 203 of the lower battery stack 201, the air is sent in such a manner as to perpendicularly hit against a left major surface of the lower bus bar 241. As a result, the air actively exchanges heat with the lower bus bar 241 to effectively cool the whole lower bus bar 241. The air after exchanging heat with the lower bus bar 241 is discharged to the outside via the opening 214 illustrated in
Heat exchange in the upper junction box 232 is similar to that in the lower junction box 231. That is, air is introduced into the upper battery stack 202 from the upper cooling air introduction passage 212. Then, after cooling each of the battery cells 203 of the upper battery stack 202, the air is introduced into the upper junction box 232. The air after cooling the upper battery stack 202 exchanges heat with the upper bus bar 242. This effectively cools the upper bus bar 242 and the main relay 222 (
Also in the upper junction box 232, the direction of the flow of air that flows from the upper battery stack 202 into the upper junction box 232 faces the major surface of the upper bus bar 242. As a result, the air actively exchanges heat with the upper bus bar 242 to effectively cool the whole upper bus bar 242. The air after exchanging heat with the upper bus bar 242 is discharged to the outside via the opening 213 illustrated in
With reference to
With reference to
As described above, the positioning unit 252 is formed on the lower cooling air introduction passage 211, whereas the positioning unit 251 is formed on the lower junction box 231. This enables exactly specifying the relative position between the lower battery stack 201 and the upper battery stack 202 in the up-down direction and in the right-left direction. In addition, a dedicated part for positioning is not used, whereby it is possible to simplify the whole structure of the battery stack structure 15.
With reference to
A terminal 29 is formed in the vicinity of the terminal 27, on an upper surface of the upper junction box 232. The terminal 29 is coupled to the upper bus bar 242 illustrated in
A recess 28 is formed in such a manner as to partially penetrate the upper junction box 232 in the up-down direction. The protrusion 26 of the lower junction box 231 is inserted into the recess 28 of the upper junction box 232. With this structure, the terminal 27, which is coupled to the lower bus bar 241 of the lower junction box 231, is led onto the upper surface of the upper junction box 232. Moreover, the protrusion 26 is inserted and fitted in the recess 28, which structure enables easy positioning of the lower junction box 231 and the upper junction box 232. Furthermore, routing of a high voltage cable that is coupled to the lower bus bar 241 is easy, and a wiring space and a working space for wiring can be dispensed with.
With reference to
With reference to
With reference
With reference to
According to this embodiment described above, the following main effects are obtained.
In this embodiment, as illustrated in
As illustrated in
The inclination of the bus bar 24, as illustrated in FIG. 7A, makes the bus bar 24 and air more actively exchange heat with each other in the junction box 23. Moreover, the flow rate of air that passes through between the battery cells 203 is adjusted by the straightening effect, whereby temperatures of the battery cells 203 are made uniform.
As illustrated in
As illustrated in
The protrusion 26, which contains the terminal 27, of the lower junction box 231, is inserted in the recess 28 of the upper junction box 232, as illustrated in
The bus bar 24 has the wide part 244, as illustrated in
The embodiments of the present disclosure has been described above. It is noted that the present disclosure is not limited to the above embodiments. Various modifications may be made without departing from the scope of the present disclosure. The above embodiments may be combined with each other.
In one example, in the battery stack structure 15 that is described with reference to
Number | Date | Country | Kind |
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2020-047614 | Mar 2020 | JP | national |