Preform insert for battery module

Abstract

The invention relates to a preformed insert for a battery module. A battery module having a preformed insert is provided. The battery module may include a plurality of battery cells configured to store and supply electrical power and a cell holder configured to support the battery cells. The preformed insert may be disposed relative to the cell holder and the battery cell and formed to include a potting material shaped to define a plurality of coolant channels surrounding the battery cell.

Description

Technical Field

[0001] The present disclosure relates to cooling battery cells, such as but not necessarily limited to cooling battery cells included within battery modules for the purpose of storing and supplying electrical power to a vehicle. Background Art

[0002] A rechargeable energy storage system (RESS) can be configured to store and supply electrical power for a variety of applications, and one of the more common types of RESS includes a plurality of battery cells arranged into one or more battery modules. Such a RESS can be included on a vehicle to store and supply electrical power for a main bus or high voltage (HV) bus and / or an auxiliary bus or low voltage (LV) bus. Because battery cells tend to generate heat when storing and supplying electrical power, it can be advantageous for an associated battery module to operate with a cold plate or other external element of a cooling system to conduct thermal energy away from the battery module. Such a cooling system can include a static epoxy filler or other hardened fluid to provide a fixed heat path of immovable material, thus facilitating the conduction of thermal energy away from the battery cells. The use of such a filler can be problematic because the filler typically requires multiple manufacturing steps or processes, including steps or processes associated with pouring the filler material around the battery cells into the battery module, sealing the battery module, or otherwise restricting the infiltration of the filler material into undesired areas, and the impregnation and in some cases heating times required for the poured filler to harden. Summary of the Invention

[0003] One aspect of the present disclosure relates to a preformed insert that is operable to conduct thermal energy away from a battery cell without having to pour a filler or other hardened material into an associated battery module or otherwise perform a labor-intensive and time-consuming manufacturing process. The preformed insert can be formed from a potting material that is shaped to define a cavity for receiving the battery cell and a coolant passage for circulating coolant relative thereto. The battery cell can simply be press-fitted or otherwise inserted into the cavity, and a cooling fluid can thereafter be circulated through the coolant passage to conduct thermal energy away from the battery cell. The ability to circulate a coolant through the coolant passage can be advantageous relative to a heat path having a fixed or immovable filler because the circulation of the coolant tends to provide greater heat distribution and efficiency.

[0004] One aspect of the present disclosure relates to a battery module. The battery module can include a plurality of battery cells configured to store and supply electrical power, a cell holder configured to support the battery cells, and a preformed insert disposed relative to the cell holder and the battery cells. The preformed insert can include a potting material that is shaped to define a plurality of coolant passages around the battery cells.

[0005] The preformed insert may include a plurality of unit cavities interspersed with coolant channels, optionally wherein the unit cavities are formed within the potting material to laterally surround a respective one of the battery cells.

[0006] The preformed insert may include a two-piece construction having an upper portion preformed separately from a lower portion and an interlock configured to attach the upper portion to the lower portion.

[0007] The unit cavity may include an upper end portion near the top of the battery cell and a lower end portion near the bottom of the battery cell.

[0008] The preformed insert may be configured to provide an upper interference fit between the upper end portion and the top of the battery cell and a lower interference fit between the lower end portion and the bottom of the battery cell.

[0009] The upper interference fit and the lower interference fit may be provided with respective upper and lower bulges formed within the potting material.

[0010] The upper interference fit and the lower interference fit may be provided with respective upper O-rings and / or gaskets and lower O-rings and / or gaskets disposed within the potting material.

[0011] The preformed insert may include a plurality of coolant bands disposed within the coolant channels, optionally wherein the coolant bands define coolant passages for coolant to flow through the coolant channels.

[0012] The preformed insert may include a thermal interface material disposed between the coolant bands and the battery cells, optionally wherein the thermal interface material is configured to support heat conduction between the coolant bands and the battery cells.

[0013] The potting material may include a thermally conductive material having a closed-cell foam structure.

[0014] The unit cavity may include an upper end portion near the top of the battery cell, a lower end portion near the bottom of the battery cell, and an intermediate portion between the upper and lower end portions, optionally wherein the upper and lower end portions are narrower than the intermediate portion, and the intermediate portion defines the coolant channel.

[0015] The battery cells may be arranged in a plurality of rows, and the coolant channels may be shaped such that the intermediate portions of the cavities in each respective row are fluidly interconnected.

[0016] The cell holder may include a coolant inlet and a coolant outlet, wherein the coolant inlet and the coolant outlet are fluidly interconnected with respective intermediate portions of the unit cavities.

[0017] One aspect of the present disclosure relates to a method for manufacturing a battery module. The method may include: receiving a cell holder; receiving a plurality of battery cells; positioning a preformed insert within the cell holder, the preformed insert including a potting material formed to define a plurality of cell cavities dispersed relative to a plurality of coolant channels; and pressing the battery cells into a respective one of the cell cavities.

[0018] The method may include forming the preformed insert such that the cell cavity includes an upper end portion, a lower end portion, and an intermediate portion between the upper end portion and the lower end portion, optionally wherein the upper end portion and the lower end portion are narrower than the intermediate portion, and the intermediate portion defines a coolant channel.

[0019] The method may include forming the preformed insert such that the battery cells are arranged in a plurality of rows, and the intermediate portions of the cavities in each respective row are fluidly interconnected with each other to define a coolant channel.

[0020] The method may include forming the preformed insert from a thermally conductive material having a closed-cell foam structure.

[0021] The method may include securing the battery cells within the preformed insert without using cast epoxy or fluid adhesives, and securing the preformed insert within the cell holder.

[0022] One aspect of the present disclosure relates to a vehicle. The vehicle may include an electric motor configured to convert electrical power into mechanical power suitable for propelling the vehicle and a rechargeable energy storage system (RESS) having one or more energy modules configured to store and supply electrical power. The energy modules may each include: a plurality of energy cells configured to store and supply electrical power; a cell holder configured to support the energy cells; a preformed insert having a potting material formed to define a plurality of cell cavities for receiving the energy cells and a plurality of coolant channels for defining a path for coolant to flow between the cell cavities relative to the energy cells; a bus bar configured to electrically interconnect the energy cells, optionally wherein the bus bar is connected to a portion of the energy cell that extends beyond the top surface of the preformed insert; and a coolant system configured to circulate coolant through the coolant channels to facilitate conduction of thermal energy away from the energy cells.

[0023] The energy cells may be cylindrical battery cells, and the potting material is molded from a thermally conductive material having a closed-cell foam structure.

[0024] The cell cavity may be a through-hole formed to include an upper end portion, a lower end portion, and an intermediate portion, optionally wherein the upper end portion and the lower end portion are narrower than the intermediate portion, and the intermediate portion defines a coolant channel.

[0025] The present invention provides the following technical solutions.

[0026] Technical solution 1. A battery module, comprising:

[0027] A plurality of battery cells configured to store and supply electric power;

[0028] A cell holder configured to support the battery cells; and

[0029] A preformed insert disposed relative to the cell holder and the battery cells, the preformed insert including a potting material formed to define a plurality of coolant channels for the battery cells.

[0030] Technical solution 2. The battery module according to technical solution 1, wherein:

[0031] The preformed insert includes a plurality of cell cavities fluidly interconnected with the coolant channels, wherein the cell cavities are formed in the potting material to laterally surround a respective one of the battery cells.

[0032] Technical solution 3. The battery module according to technical solution 2, wherein:

[0033] The preformed insert includes a two-piece construction having an upper part preformed separately from a lower part and an interlock configured to attach the upper part to the lower part.

[0034] Technical solution 4. The battery module according to technical solution 2, wherein:

[0035] The cell cavity includes an upper end portion near the top of the battery cell and a lower end portion near the bottom of the battery cell; and

[0036] The preformed insert is configured to provide an upper interference fit between the upper end portion and the top of the battery cell and a lower interference fit between the lower end portion and the bottom of the battery cell.

[0037] Technical solution 5. The battery module according to technical solution 4, wherein:

[0038] The upper interference fit and the lower interference fit are provided with corresponding upper and lower bulges formed in the potting material.

[0039] Technical solution 6. The battery module according to technical solution 4, wherein:

[0040] The upper interference fit and the lower interference fit are provided with corresponding upper O-rings and / or washers and lower O-rings and / or washers disposed within the potting material.

[0041] Aspect 7. The battery module according to aspect 2, wherein:

[0042] The preformed insert includes a plurality of coolant bands disposed within the coolant channels, wherein the coolant bands define coolant passages for coolant to flow through the coolant channels.

[0043] Aspect 8. The battery module according to aspect 7, wherein:

[0044] The preformed insert includes a thermal interface material disposed between the coolant bands and the battery cells, wherein the thermal interface material is configured to support heat conduction between the coolant bands and the battery cells.

[0045] Aspect 9. The battery module according to aspect 2, wherein:

[0046] The potting material includes a thermally conductive material having a closed-cell foam structure.

[0047] Aspect 10. The battery module according to aspect 2, wherein:

[0048] The cell cavity includes an upper end portion near the top of the battery cell, a lower end portion near the bottom of the battery cell, and an intermediate portion between the upper end portion and the lower end portion, wherein the upper end portion and the lower end portion are narrower than the intermediate portion, and the intermediate portion defines the coolant channel.

[0049] Aspect 11. The battery module according to aspect 10, wherein:

[0050] The battery cells are arranged in a plurality of rows; and

[0051] The coolant channels are shaped such that the intermediate portions of the cavities in each corresponding row are fluidly interconnected.

[0052] Aspect 12. The battery module according to aspect 11, wherein:

[0053] The cell holder includes a coolant inlet and a coolant outlet, wherein the coolant inlet and the coolant outlet are fluidly interconnected with the corresponding intermediate portions of the cell cavity.

[0054] Aspect 13. A method for manufacturing a battery module, comprising:

[0055] Position a preformed insert within a cell holder, the preformed insert including potting material formed to define a plurality of cell cavities dispersed relative to a plurality of coolant channels; and

[0056] Press a plurality of battery cells into a respective one of the cell cavities.

[0057] Aspect 14. The method according to aspect 13, further comprising:

[0058] Form the preformed insert such that each of the cell cavities includes an upper end portion, a lower end portion, and an intermediate portion, wherein the intermediate portion is between the upper end portion and the lower end portion, is narrower than the upper end portion and the lower end portion, and defines the coolant channel.

[0059] Aspect 15. The method according to aspect 14, further comprising:

[0060] Form the preformed insert such that the battery cells are arranged in a plurality of rows, and the intermediate portions of the cavities in each respective row are fluidly interconnected with each other to define the coolant channel.

[0061] Aspect 16. The method according to aspect 15, further comprising:

[0062] Form the preformed insert from a thermally conductive material having a closed-cell foam structure.

[0063] Aspect 17. The method according to aspect 16, further comprising:

[0064] Attach the battery cells within the preformed insert and attach the preformed insert within the cell holder without using cast epoxy or fluid adhesives.

[0065] Aspect 18. A vehicle, comprising:

[0066] An electric motor configured to convert electrical power into mechanical power for propelling the vehicle; and

[0067] A rechargeable energy storage system (RESS) having one or more energy modules configured to store and supply the electrical power, wherein the energy modules each include:

[0068] A plurality of energy cells configured to store and supply the electrical power;

[0069] A cell holder configured to support the energy cells;

[0070] A preformed insert having a potting material formed to define a plurality of cell cavities for receiving the energy cells and a plurality of coolant channels for defining a path for coolant flow relative to the energy cells between the cell cavities;

[0071] Busbars configured for electrically interconnecting the energy cells, the busbars being connected to portions of the energy cells that extend beyond the top surface of the preformed insert; and

[0072] A coolant system configured to circulate the coolant through the coolant channels to facilitate conduction of thermal energy away from the energy cells.

[0073] Aspect 19. The vehicle according to Aspect 18, wherein:

[0074] The energy cells are cylindrical battery cells; and

[0075] The potting material is molded from a thermally conductive material having a closed-cell foam structure.

[0076] Aspect 20. The vehicle according to Aspect 19, wherein:

[0077] The cell cavities are through-holes formed to include an upper end portion, a lower end portion, and an intermediate portion, wherein the upper end portion and the lower end portion are narrower than the intermediate portion, and the intermediate portion defines the coolant channels.

[0078] When taken in conjunction with the drawings, these features and advantages, as well as other features and advantages of the present teachings, will become apparent from the following detailed description of the modes for carrying out the present teachings. It should be understood that even though the following drawings and embodiments may be described separately, the individual features thereof may be combined into additional embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] The drawings, which are incorporated in and form a part of this specification, illustrate implementations of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0080] Figure 1 A vehicle is illustrated in accordance with a non-limiting aspect of the present disclosure.

[0081] Figure 2 A partial exploded view of a battery module is illustrated in accordance with a non-limiting aspect of the present disclosure.

[0082] Figure 3 A partially cut-away perspective view of a preformed insert is illustrated in accordance with a non-limiting aspect of the present disclosure.

[0083] Figure 4The perspective view of a battery module according to a non - restrictive aspect of the present disclosure is illustrated.

[0084] Figure 5 Illustrated is a Figure 4 schematic side view of a battery module according to a non - restrictive aspect of the present disclosure, the battery module having a pre - formed insert with interlocks.

[0085] Figure 6 Illustrated is a Figure 4 schematic alternative side view of a battery module according to a non - restrictive aspect of the present disclosure.

[0086] Figure 7 Illustrated is a Figure 4 schematic alternative side view of a battery module according to a non - restrictive aspect of the present disclosure, the battery module having a pre - formed insert with coolant bands.

[0087] Figure 8 The flow chart of a method for manufacturing a battery module according to a non - restrictive aspect of the present disclosure is illustrated. Detailed Description

[0088] As needed, detailed embodiments of the present disclosure may be disclosed herein; however, it is understood that the disclosed embodiments may be merely exemplary of the disclosure that may be implemented in various and alternative forms. The drawings may not necessarily be to scale; some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one of ordinary skill in the art to use the present disclosure in various ways.

[0089] Figure 1Illustrated is a vehicle 12 according to a non - limiting aspect of the present disclosure. The vehicle 12 may be interchangeably referred to as an electric or hybrid vehicle 12, which may include a traction motor 14 that is operable to convert electrical power into mechanical power for the purpose of doing work, such as for mechanically powering a driveline 16 to propel the vehicle. The vehicle 12 is illustrated as a hybrid type because the power system 16 optionally includes an internal combustion engine (ICE) 18 for generating mechanical power. Alternatively, the vehicle 12 may omit the electric motor 14 and instead be propelled solely by the ICE 18. The power system 16 may include components that facilitate the transfer of rotational force from the traction motor 14 and / or the ICE 18 to one or more of the wheels 20, 22, 24, 26. The vehicle 12 may include a rechargeable energy storage system (RESS) 30 that is configured to store and supply electrical power to the traction motor 12 and / or other components, systems, etc. 32 on the vehicle 12, such as via a first bus 34 and a second bus 36. The vehicle 12 may include a vehicle controller 38 to facilitate monitoring, controlling, measuring, and otherwise directing operations, tasks, etc. on the vehicle 12, which may include performing measurements, obtaining readings, or otherwise collecting data to facilitate diagnosing a constraint event and accordingly managing the RESS 30 to mitigate its effects while keeping the operation of the RESS 30 within defined operating boundaries.

[0090] Figure 2 Illustrated is a partial exploded view of a battery module according to a non - limiting aspect of the present disclosure. The battery module 44 may be included as part of the RESS 30 to house a plurality of battery cells 46 that are operable to store and supply electrical power. The RESS is shown with respect to including a single battery module 44 for simplicity, as the present disclosure fully contemplates a RESS that includes additional battery modules 44, battery modules 44 that include more or fewer battery cells 46 than shown. The battery module 44 may include additional components for electrically interconnecting the battery cells 46 to each other and / or to other systems on the vehicle 12. The battery cells 46 may be constituted of a variety of components operable to store and supply electrical power. The battery cells 46 may include lithium - ion materials or other chemical materials suitable for storing and supplying electrical power, optionally where some of the battery cells 46 have a mixture or different chemistry from some of the other battery cells 46. However, the use of the battery cells 46 is presented for non - limiting purposes, as the present disclosure fully contemplates that the battery cells 46 are other types of energy cells capable of storing and / or supplying electrical power, such as but not necessarily limited to energy cells constituted of capacitors, supercapacitors, fuel cells, or other types of energy components.

[0091] The battery module 44 may include a cell holder 50 configured to support battery cells 46. The cell holder 50 may be formed as a rigid structure, such as formed from a variety of stamped or molded materials assembled into a housing or other structure adapted to enclose the battery cells 46. For non-limiting purposes, the cell holder 50 is shown as including four side members 52, 54, 56, 58 and opposing top member 60 and bottom member 62, which may be interconnected, welded, fastened, or otherwise attached to each other. The bottom member 62 may have a lower side that rests against a cold plate 66 or other elements of a cooling system (not shown) or otherwise mates with the cold plate 66 or other elements. One aspect of the present disclosure relates to a preformed insert 68 included within the battery module 44. The preformed insert 68 may be operable to conduct thermal energy away from the battery cells 46 without having to pour a filler or other hardening material into the associated battery module 44 or otherwise perform a labor-intensive and time-consuming manufacturing process. As shown in the Figure 3 partially cut-away perspective view shown in, the preformed insert 68 may be formed from a potting material shaped to define a cavity 70 for receiving the battery cells 46 and coolant channels 72 for circulating a dielectric coolant or other suitable coolant provided via a cooling system relative to the battery cells 46. The battery cells 46 may be press-fitted or otherwise inserted within the cavity 70, and a cooling fluid may thereafter be circulated through the coolant channels 72 to conduct thermal energy away from the battery cells 46. Since the circulation of the coolant tends to provide greater heat distribution and efficiency, the ability to circulate the coolant through the coolant channels 72 (the coolant channels 72 are not individually labeled and are shown as representative dashed lines for simplicity of presentation) may be advantageous relative to a thermal path having a fixed or immovable filler.

[0092] The preformed insert 68 may include cell cavities 70 arranged in a plurality of rows and columns, optionally where the coolant channels 72 in each row are fluidly interconnected. The preformed insert 68 may include a coolant inlet 76 and a coolant outlet 78 for each of the coolant channels 72, which may optionally include conical or other shaped expansion elements 80, 82 for dispersing the coolant therethrough. Returning to Figure 2 , the coolant inlet 76 and the coolant outlet 78 may mate with an inlet coolant port 86 and an outlet coolant port 88 (which are not individually labeled) included within the cell holder 50 to facilitate fluid connection of the coolant inlet 80 and the coolant outlet 82 to the cooling system. As Figure 3As shown in the partial cross-sectional view, the preformed insert 68 may optionally include coolant bands 90 disposed within one or more of the coolant channels 72. The coolant bands 90 may be rigid structures for defining coolant passages for coolant to flow through the coolant channels 72. The coolant bands 90 may be divided into an upper section 92 and a lower section 94 such that coolant fluid may be delivered through a respective one of the coolant inlets 76 for communication through the upper section 92, after which the coolant travels to the rear end of the associated coolant band 90 where the coolant may reverse direction to flow back toward a respective coolant outlet 78 positioned adjacent the associated lower section 94. The material used to form the preformed insert 68 may be composed of a thermally conductive material having a closed-cell foam structure or other types of materials suitable for conducting heat energy away from the battery cells 46. The potting material may be semi-rigid or less rigid than the housing and / or the coolant bands 90. The potting material may be dense and / or hard enough to facilitate a press fit with the battery cells 46 and / or support the battery cells 46 in other ways contemplated herein.

[0093] Figure 4 A perspective view of a battery module in accordance with a non-limiting aspect of the present disclosure is illustrated. The battery module 44A may be similar to the battery module described above with respect to including a cell retainer 50 and a plurality of battery cells 46 positioned within a preformed insert 68. The battery module 44A is shown to include fewer battery cells 46 in the battery module 44 described above in order to demonstrate the advantageous ability of the present disclosure to support modular construction, whereby a plurality of battery cell monitoring modules may be joined together to form a RESS 30, such as a plurality of modules being able to operate together in series and / or parallel. The ability to selectively interconnect a plurality of battery modules 44A may be advantageous in tailoring the size, capacity, etc. of the RESS 30 for a vehicle and / or other devices employing the same. One aspect of the present disclosure contemplates a preformed insert 68 having different configurations depending on the desired manner for circulating coolant through the coolant channels 72. The ability to circulate coolant through the coolant channels 72 may be advantageous in providing an immersion cooling environment, whereby the coolant may circulate relative to the battery cells 46 and optionally contact the battery cells 46 in order to optimize heat conduction and cooling to a maximum extent. As those skilled in the art may appreciate, the ability to provide improved cooling compared to static or immovable fillers may be advantageous in limiting the operating temperature of the RESS 30, which in turn may improve the performance, efficiency, lifespan, etc. of the battery cells 46.

[0094] Figure 5 Illustrated is taken from Figure 4Partial schematic side view, showing a preformed insert 68A having an interlocking configuration according to a non-limiting aspect of the present disclosure. The interlocking configuration may correspond to a preformed insert 68A having a two-piece construction, having an upper portion 90 preformed separately from a lower portion 92 and an interlock 94 configured to attach the upper portion 90 to the lower portion 92. The interlock 94 may include features adapted to seal, connect, or otherwise attach the upper and lower portions together such that coolant flowing through the respective coolant channels 72 may be retained therein. The interlock 94 may be operable to allow the lower portion 92 to be inserted into the unit holder 50 such that the battery cell 46 may be inserted into a corresponding one of the battery cavities 70, and subsequently the upper portion 90 may be assembled thereon. The interlock 94 may also be operable to allow the lower portion 90 to be inserted into the unit holder 50 such that the upper portion 90 may be assembled thereon, and subsequently, after the preformed insert 68A is assembled, the battery cell 46 may be fitted into the unit cavity 70. The unit cavity 70 may include an upper end portion 98 near the top of the battery cell 46 and a lower end portion 100 near the bottom of the battery cell 46.

[0095] The preformed insert 68A may include an upper bulge 102 and a lower bulge 104 configured to provide an upper interference fit between the upper end portion 98 and the top of the battery cell 46 and a lower interference fit between the lower end portion 100 and the bottom of the battery cell 46. The interference fit may be operable to retain the coolant within the respective coolant channels 72. The upper end portion 98 and the lower end portion 100 of the unit cavity 70 may be narrower than the intermediate portion 106 such that the intermediate portion 106 may be used to define the respective coolant channels 72. The preformed potting material forming the preformed insert 68A may be shaped to at least partially or fully laterally surround the battery cell 46 such that the unit cavity 70 may be dispersed relative to the coolant channels 72. The unit cavity 70 may be interconnected with the coolant channels 72 or form part of the coolant channels 72 such that the coolant circulating through the coolant channels 72 may physically contact the sides of the battery cell 46 before passing through a tunnel section connecting to another one of the unit cavities 70. The unit cavity 70 may be a through-hole shaped such that the top surface 108 and the bottom surface 110 of the battery cell 46 may extend beyond the corresponding top surface 112 and bottom surface 114 of the preformed insert 68A. The unit holder 50 may be correspondingly shaped such that the top extension 116 and the bottom extension 118 may be shaped to at least partially extend over the battery cell 46. Bus bars or other circuit components 120 may be included for electrically interconnecting the battery cells 46 to each other.

[0096] Figure 6 Illustrated is taken from Figure 4Partial schematic side view, showing a preformed insert 68B with an overall configuration according to a non-limiting aspect of the present disclosure. The overall configuration may be characterized by a preformed insert 68B having an integral construction. The overall configuration is shown as including a seal 126, such as an O-ring and / or gasket, to provide an upper interference fit between the upper end portion 98 and the top of the battery cell 46 and a lower interference fit between the lower end portion 100 and the bottom of the battery cell 46. The seal 126 may be formed of rubber or other material different from the potting material and is used in place of the above-described upper and lower ridges to improve tolerance requirements, formation control, and / or other processes required to form the ridges. In other words, instead of tightly forming the preformed insert 68B to include ridges, the preformed insert 68B may instead be formed to include a relief, and the seal may be disposed within the relief to seal the respective coolant channels 72. One aspect of the present disclosure contemplates that the seal 126 has elastic or spring characteristics such that the seal 126 can be slightly compressed to insert into the respective unit cavity 70, and subsequently the seal can slightly expand to retain itself therein.

[0097] Figure 7 A partial schematic side view taken from Figure 4 shows a preformed insert 68C with an overall configuration having a coolant strip 90 according to a non-limiting aspect of the present disclosure. The coolant strip 90 may be similar to the above-described coolant strip 90, which is shown as being optionally disposed relative to the thermal interface material 132. The thermal interface material 132 may be disposed between the coolant strips 90 in the battery cell 46 to support heat conduction therebetween. The coolant strip 90 may be an optionally contained medium separated from the battery cell 46 such that contact between the coolant therein and the battery cell 46 can be avoided, i.e., the coolant can flow through the strip 90 without immersing or otherwise contacting the battery cell 46 to carry away heat from the battery cell 46 by heat conduction. The ability to circulate the coolant through the coolant strip 90 may be advantageous in limiting the possibility of coolant leakage from the preformed insert 68C and / or in simplifying the manufacturability of the preformed insert 68C by allowing the insert 68C to be formed without the need for the above-described ridges and / or seals.

[0098] Figure 8FIG. 140 is a flow chart of a method for manufacturing a battery module 44 in accordance with a non-limiting aspect of the present disclosure. Block 142 relates to a forming process by which a preformed insert 68 can be formed. The forming process can include forming the preformed insert 68 such that the cell cavity 70 includes an upper end portion, a lower end portion, and an intermediate portion between the upper and lower end portions, wherein the upper and lower end portions are narrower than the intermediate portion, and the intermediate portion defines a coolant channel 72. The forming process can include forming the preformed insert 68C such that the battery cells 46 are arranged in a plurality of rows, and the intermediate portions of the cavities 70 in each respective row are fluidly interconnected with each other to define the coolant channel 72. The forming process can include forming the preformed insert 68 from a thermally conductive material having a closed cell foam structure. Block 144 relates to a process for receiving and / or manufacturing a cell holder 50. Block 146 relates to a process for receiving a plurality of battery cells 46. Block 148 relates to an assembly process for positioning the preformed insert 68 within the cell holder 50 and thereafter or concurrently press-fitting or otherwise inserting the battery cells 46 into respective ones of the cell cavities 70. The assembly process can optionally be performed by securing the battery cells 46 within the preformed insert 68 and securing the preformed insert 68 within the cell holder 50 without the use of poured epoxy or fluid adhesives.

[0099] As described above, the present disclosure relates to a preformed cell-to-cell barrier potting material that is molded to have built-in channels that provide a cooling function for cells within a battery module. The cell-to-cell barrier material can be formed as a part that can be assembled during battery module manufacturing to reduce manufacturing costs and cycle times by eliminating the need for injection machines, inventory for potting cure times in an assembly line, etc. The potting material can be formed with built-in channels for dielectric coolant flow to enable immersion cooling without mass penalties due to large coolant volumes within the battery module. The potting material can be a preformed closed cell foam material that provides a thermal and electrical barrier between cells. The potting material can be shaped to enclose coolant flow channels that replace cold plates and / or cooling straps and interface directly with the remainder of the cooling system (pumps, filters, hoses, heat exchangers). The potting material can be shaped to form cavities for receiving battery cells and / or other types of energy cells, with coolant channels formed relative to the cells, which can have cylindrical, prismatic, pouch, or other shapes and / or dimensions.

[0100] Although various embodiments have been described, the description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that more embodiments and implementations within the scope of the embodiments are possible. Unless specifically restricted, any feature of any embodiment can be used in combination with or substituted for any other feature or element in any other embodiment. Thus, the embodiments are not restricted except in accordance with the appended claims and their equivalents. Additionally, various modifications and changes can be made within the scope of the appended claims. Although several modes for carrying out many aspects of the present teachings have been described in detail, those familiar with the fields involved in these teachings will recognize various alternative aspects for practicing the teachings within the scope of the appended claims. It is intended that all content included in the above description or shown in the accompanying drawings be construed as illustrative and examples of the overall scope of alternative embodiments that would be recognized by those of ordinary skill in the art, such alternative embodiments being implied by the included content, structurally and / or functionally equivalent to the included content, or otherwise made apparent based on the included content, and not limited solely to those explicitly depicted and / or described embodiments.

Claims

1. A battery module, comprising: a plurality of battery cells configured to store and supply electrical power; a cell holder configured to support the battery cell; and A preformed insert is disposed relative to the cell holder and the battery cell, the preformed insert including a potting material shaped to define a plurality of coolant channels for the battery cell.

2. The battery module according to claim 1, wherein: The preformed insert includes a plurality of cell cavities fluidly interconnected with the coolant channels, wherein the cell cavities are formed within the potting material to laterally surround a respective one of the battery cells.

3. The battery module according to claim 2, wherein: The preformed insert includes a two-piece construction having an upper portion preformed separately from a lower portion and an interlocking piece configured for attaching the upper portion to the lower portion.

4. The battery module according to claim 2, wherein: The cell cavity includes an upper end portion proximate a top portion of the battery cell and a lower end portion proximate a bottom portion of the battery cell; and The preformed insert is configured to provide an upper interference fit between the upper end and the top of the battery cell and a lower interference fit between the lower end and the bottom of the battery cell.

5. The battery module according to claim 4, wherein: The upper interference fit and the lower interference fit are provided with corresponding upper and lower ridges formed in the potting material.

6. The battery module according to claim 4, wherein: The upper interference fit and the lower interference fit are provided with respective upper and lower O-rings and / or washers disposed within the potting material.

7. The battery module according to claim 2, wherein: The preform insert includes a plurality of coolant bands disposed within the coolant channel, wherein the coolant bands define coolant passages for coolant to flow through the coolant channel.

8. The battery module according to claim 7, wherein: The pre-formed insert includes a thermal interface material disposed between the coolant ribbon and the battery cell, wherein the thermal interface material is configured to support thermal conduction between the coolant ribbon and the battery cell.

9. A method for manufacturing a battery module, comprising: positioning a preformed insert within the cell holder, the preformed insert comprising a potting material formed to define a plurality of cell cavities interspersed relative to the plurality of coolant channels; and A plurality of battery cells are pressed into a corresponding one of the cell cavities.

10. A vehicle comprising: an electric motor configured to convert electrical power into mechanical power suitable for propelling the vehicle; as well as A rechargeable energy storage system (RESS) having one or more energy modules configured to store and supply the electric power, wherein the energy modules respectively include: a plurality of energy units configured to store and supply said electrical power; a unit holder configured to support the energy unit; a preformed insert having a potting material shaped to define a plurality of cell cavities for receiving the energy cell and a plurality of coolant channels for defining passages for coolant to flow between the cell cavities relative to the energy cell; a bus bar configured to electrically interconnect the energy units, the bus bar being connected to portions of the energy units extending beyond the top surface of the preformed insert; and a coolant system configured to circulate the coolant through the coolant channels to facilitate conducting heat away from the energy units.

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