System and method for cooling battery

Abstract

A battery cooling architecture or assembly includes a cooling volume surrounding the entire perimeter of a battery cell structure with a uniform flow distribution for all cells. The cooling volume may be placed at any location along the axial length of the cell. The cooling volume can directly cool a selected portion of the axial length of the cell, and in alternative embodiments, a larger axial length of the cell can be indirectly cooled by means of the added sleeve.

Description

Technical Field

[0001] The present invention relates to a system for cooling a battery and a method of cooling a battery, and more particularly, to a battery cooling assembly including a cooling volume. Background Art

[0002] Conventional cooling techniques typically cannot maintain a very uniform cell temperature distribution, which results in non-uniform and accelerated cell degradation. Additionally, in many cases, conventional cooling techniques also face very significant challenges in ensuring very uniform battery cell placement. Further, these techniques require complex assembly processes that have many complex assembly steps, which not only require a very large capital investment, but also result in significant yield losses due to these many complex assembly steps. All of these problems exist in many cooling architectures.

[0003] Without adding a thermal mitigation agent, conventional cooling architectures cannot meet the safety requirements for cell thermal runaway and propagation. The addition of such an agent, which is in many cases a low-density thermal barrier variant, is one of the more complex parts of the battery module assembly process, which also increases the complexity of the module design and causes potential further assembly problems in the assembly line.

[0004] Moreover, conventional cooling architectures are typically designed to cool battery cells, but cannot directly cool the conductive layer. The conductive layer typically dissipates heat to the battery cells, which are then cooled by cooling elements at different locations. This results in hot spots in the conductive layer and overheating of cells in specific regions, which further compromises cell temperature uniformity.

[0005] Conventional cooling architectures typically include some components that, although made of materials that may potentially provide a structural advantage for the battery pack, generally do not possess such an advantage.

[0006] Accordingly, there is a need for an improved battery cooling system that addresses the above disadvantages. Summary of the Invention

[0007] A battery cooling architecture or component includes a cooling volume that surrounds the entire perimeter of a battery cell structure and has a uniform flow distribution for all battery cells. The battery cooling architecture may alternatively be referred to as a battery cooling system. The cooling volume may be placed at any location along the axial length of the cell. The cooling volume may directly cool a selected portion of the axial length of the cell and, in an alternative embodiment, is capable of indirectly cooling a greater axial length of the cell by means of an added sleeve. The cooling volume component also enables the addition of many different variations of different elements to a general battery cooling component to further enhance its primary operating function. The battery cooling component is designed to allow for mass production of a battery cooling component that can be used not only as a cooling and safety architecture but also as a battery module assembly fixture.

[0008] The techniques disclosed herein also relate to a method of manufacturing a battery cooling architecture that includes a cooling volume that surrounds the entire perimeter of one or more battery cells and provides a uniform flow distribution for all battery cells. The components for forming the cooling volume are designed such that the components of the cooling volume architecture can be joined together in a single step or, alternatively, can be joined together in sequential steps. The alternative designs for the cooling volume components disclosed herein enable their assembly to be completed in one step or a series of steps.

[0009] In one aspect of the present disclosure in accordance with the techniques disclosed herein, a battery cooling system for use with one or more battery cells includes: a cooling volume component that defines an internal chamber, the cooling volume component including an inlet and an outlet, each of the inlet and the outlet being in fluid communication with the internal chamber; and a cooling modular structure that is spaced apart from the cooling volume component, wherein the cooling volume component and the cooling modular structure cool the one or more battery cells and fluid travels through the inlet, internal chamber, and outlet of the cooling volume component.

[0010] In another aspect, a conductive layer is connected to the one or more battery cells and the cooling modular structure is placed in contact with the conductive layer.

[0011] In another aspect, each of the one or more battery cells includes a first end and a second end opposite the first end, a conductive layer is connected to the first end of each battery cell, and the cooling modular structure is placed in contact with the second end of each battery cell.

[0012] In another aspect, one or more battery cells define a perimeter therearound and the cooling volume component extends over the entire extent of the perimeter.

[0013] On the other hand, each of the one or more battery cells includes a first end and a second end opposite the first end, and each battery cell includes an axial length extending between the first end and the second end.

[0014] On the other hand, one of the first end and the second end is the thermally ventilated side of each battery cell.

[0015] On the other hand, the cooling volume assembly is positioned adjacent to the second end of each battery cell such that an outer surface of the cooling volume assembly is flush with the second end of each battery cell.

[0016] On the other hand, the cooling volume assembly is positioned at an intermediate position along the axial length of each battery cell, where the intermediate position is between the first end and the second end.

[0017] On the other hand, the cooling volume assembly is positioned in an extended position relative to each battery cell, a first portion of the cooling volume assembly is adjacent to an outer surface of each battery cell, and a second portion of the cooling volume assembly extends beyond the second end of each battery cell.

[0018] On the other hand, the cooling volume assembly is positioned in an extended position relative to each battery cell, and the cooling volume assembly extends completely beyond the second end of each battery cell.

[0019] On the other hand, the battery cooling system includes a cooling sleeve located between the cooling volume assembly and the cooling modular structure, the cooling sleeve defining a channel therethrough, the channel receiving one of the one or more battery cells therein.

[0020] On the other hand, the battery cooling system includes: a first cooling sleeve located between the cooling volume assembly and the cooling modular structure, the first cooling sleeve defining a first channel therethrough, the first channel receiving a first battery cell therein; a second cooling sleeve located between the cooling volume assembly and the cooling modular structure, the second cooling sleeve defining a second channel therethrough, the second channel receiving a second battery cell therein; and a heat transfer element coupled to the first cooling sleeve and the second cooling sleeve.

[0021] On the other hand, the battery cooling system includes a third cooling sleeve located between the cooling volume assembly and the cooling modular structure, the third cooling sleeve defining a third channel therethrough, the third channel receiving a third battery cell therein, where the first cooling sleeve is spaced apart from the second cooling sleeve by a first distance, the first cooling sleeve is spaced apart from the third cooling sleeve by a second distance, and the second cooling sleeve is spaced apart from the third cooling sleeve by a third distance, the first distance being greater than each of the second distance and the third distance.

[0022] In another aspect of the present disclosure in accordance with the techniques disclosed herein, a battery cooling system for use with a battery cell having a conductive layer coupled thereto includes: a cooling volume assembly that defines an internal chamber, the cooling volume assembly including an inlet and an outlet, each of the inlet and the outlet being in fluid communication with the internal chamber, and a cooling fluid traveling through the inlet, the internal chamber, and the outlet of the cooling volume assembly; a cooling modular structure spaced apart from the cooling volume assembly; and a cooling sleeve connected to the cooling volume assembly and the cooling modular structure and positioned between the cooling volume assembly and the cooling modular structure, the cooling sleeve defining a channel, one of the battery cells being located in the channel, wherein the cooling volume assembly, the cooling modular structure, and the cooling sleeve cool the battery cells.

[0023] In one aspect, each of the battery cells includes a first end and a second end opposite the first end, each battery cell including an axial length extending between the first end and the second end.

[0024] In another aspect, the cooling volume assembly is positioned adjacent the second end of each battery cell such that an outer surface of the cooling volume assembly is flush with the second end of each battery cell.

[0025] In another aspect, the cooling volume assembly is positioned at an intermediate position along the axial length of each battery cell, wherein the intermediate position is between the first end and the second end.

[0026] In another aspect, the cooling volume assembly is positioned in an extended position relative to each battery cell, a first portion of the cooling volume assembly being adjacent an outer surface of each battery cell and a second portion of the cooling volume assembly extending beyond the second end of each battery cell.

[0027] In another aspect of the present disclosure in accordance with the techniques disclosed herein, a battery cooling system for use with battery cells in a battery cell grid includes: a cooling volume assembly that defines an internal chamber, the cooling volume assembly including an inlet and an outlet, each of the inlet and the outlet being in fluid communication with the internal chamber; a first cooling sleeve that is engageable with the cooling volume assembly, the first cooling sleeve defining a first channel in which a first battery cell is located; a second cooling sleeve that is engageable with the cooling volume assembly, the second cooling sleeve defining a second channel in which a second battery cell is located; and a heat transfer element coupled to the first cooling sleeve and the second cooling sleeve, wherein the heat transfer element is capable of transferring thermal energy between the first cooling sleeve and the second cooling sleeve.

[0028] In one aspect, the battery cooling system includes a third cooling sleeve capable of engaging with the cooling volume component. The third cooling sleeve defines a third channel in which a third battery cell is located. The first cooling sleeve is spaced apart from the second cooling sleeve by a first distance, the first cooling sleeve is spaced apart from the third cooling sleeve by a second distance, and the second cooling sleeve is spaced apart from the third cooling sleeve by a third distance. The first distance is greater than each of the second distance and the third distance. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] To complete the description and to provide a better understanding of the present application, a set of drawings is provided. These drawings form an integral part of the description and illustrate embodiments of the present application, which should not be construed as limiting the scope of the invention, but only as examples. The drawings include the following figures:

[0030] Figure 1 A schematic diagram showing an embodiment of a battery cooling assembly and an exemplary battery according to one aspect of the present disclosure.

[0031] Figure 2A A cross-sectional side view showing an embodiment of a battery cooling assembly according to one aspect of the present disclosure as used with a battery.

[0032] Figure 2B Shows Figure 2A A bottom view of the battery cooling assembly and the battery shown in

[0033] Figure 3A A cross-sectional side view showing an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0034] Figure 3B Shows along Figure 3A The line "A-A" in Figure 3A A top view of the battery cooling assembly shown in

[0035] Figure 4A A cross-sectional side view showing another embodiment of a battery cooling assembly according to one aspect of the present disclosure as used with a battery.

[0036] Figure 4B Shows Figure 4A A bottom view of the battery cooling assembly and the battery shown in

[0037] Figure 5A A cross-sectional side view showing an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0038] Figure 5B Shows along Figure 5A The line "B-B" in Figure 5ATop view of the battery cooling assembly shown in

[0039] Figure 6 Cross-sectional side view of another embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0040] Figure 7 Shows Figure 6 Bottom view of the battery cooling assembly shown in

[0041] Figure 8 Cross-sectional side view of another embodiment of a battery cooling assembly according to one aspect of the present disclosure for use with a battery.

[0042] Figure 9 Shows Figure 8 Bottom view of the battery cooling assembly and the battery shown in

[0043] Figures 10 to 19 Cross-sectional side view of additional embodiments of a battery cooling assembly according to different aspects of the present disclosure for use with a battery.

[0044] Figure 20 Cross-sectional side view of an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0045] Figure 21 Shows along Figure 20 Line "C-C" in Figure 20 Top view of the battery cooling assembly shown in

[0046] Figure 22 Cross-sectional side view of another embodiment of a battery cooling assembly according to one aspect of the present disclosure for use with a battery.

[0047] Figure 23 Shows along Figure 22 Line "D-D" in Figure 22 Cross-sectional top view of the battery cooling assembly and the battery shown in

[0048] Figure 24A Cross-sectional side view of an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0049] Figure 24B Shows along Figure 24A Line "E-E" in Figure 24A Top view of the battery cooling assembly shown in

[0050] Figure 25A Cross-sectional side view of an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0051] Figure 25B shows a top view of the battery cooling assembly shown in Figure 25A taken along line "F-F" in Figure 25A the battery cooling assembly shown in

[0052] Figure 26A shows a cross-sectional side view of an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0053] Figure 26B shows a top view of the battery cooling assembly shown in Figure 26A taken along line "G-G" in Figure 26A the battery cooling assembly shown in

[0054] Figure 27A shows a cross-sectional side view of an alternative embodiment of a battery cooling assembly according to one aspect of the present disclosure.

[0055] Figure 27B shows a top view of the battery cooling assembly shown in Figure 27A taken along line "H-H" in Figure 27A the battery cooling assembly shown in

[0056] The same reference numerals are used throughout the present disclosure to identify the same elements. DETAILED DESCRIPTION

[0057] The following description is not restrictive but is given only for the purpose of describing the broad principles of the invention. Embodiments of the invention will be described by way of example with reference to the above figures showing the elements and results according to the invention.

[0058] Turning first to Figure 1 , a schematic diagram of an embodiment of a battery cooling assembly and an exemplary battery according to one aspect of the present disclosure is shown. As shown, the battery cooling architecture 10 includes a cooling volume assembly 20 having an inlet 22 and an outlet 24. The cooling volume assembly 20 is a structure that defines an internal region or internal chamber through which fluid can flow. Each of the inlet and outlet is in fluid communication with the internal chamber. A fluid, such as a fluid having cooling properties, can flow into the chamber via the inlet 22 in the direction of arrow "I". The fluid can circulate in the chamber of the cooling volume assembly 20 and exit through the outlet 24 in the direction of arrow "O". The cooling volume assembly 20 is positioned adjacent to a portion of the battery cell grid 40, which may include one or more battery cells in different embodiments. The fluid in the cooling volume assembly 20 absorbs heat from the battery cell grid 40. In one embodiment, one or more conductive layers 50 are connected to the ends of the battery cells in the battery cell grid 50.

[0059] The cooling architecture according to the present disclosure includes a cooling volume which, in one embodiment, is formed by a shaped metal and a connecting metal part that ensures an airtight sealed volume. As shown in more detail below, in some implementations, the cooling volume includes a circular shape or area or receiver for receiving battery cells. These circular areas or receivers accurately determine the positions of the battery cells of the entire module and also provide the necessary heat transfer area for the thermal control of the battery cells. These circular shapes are extruded, which helps to form a shape that resists buckling and also generates a spring force around the battery cells.

[0060] Go to Figure 2A and Figure 2B , side and bottom views of an embodiment of a battery cooling assembly according to one aspect of the present disclosure for use with a battery are shown respectively. In Figure 2A and Figure 2B , the battery cooling volume is positioned such that it can cool the battery cells.

[0061] In this embodiment, the battery 100 shown is an example of a battery that can be used with the battery cooling assembly 150. The battery cooling assembly 150 may alternatively be referred to as a battery cooling architecture. The battery 100 includes a number of battery cells 110, 112, 114, 116, 118, 120, 122 and 124, which are cylindrical in this embodiment. In different embodiments, the cells of the battery may have a non-cylindrical cross-section (such as a square cross-section), and the cells of the battery may have different cross-sectional sizes and / or shapes. Each of these cells has a first end 126 and a second end 128 opposite the first end 126. Each cell also includes an axial length "L" extending from the first end 126 to the second end 128.

[0062] Connected to the battery cells is a conductive layer 102, which also benefits from the cooling by the cooling assembly in addition to the cells 110, 112, 114, 116, 118, 120, 122 and 124. Referring to Figure 2B , a perimeter 130 is defined around the battery cells 110, 112, 114, 116, 118, 120, 122 and 124. The perimeter 130 is shown by a dashed line.

[0063] Returning to reference Figure 2A , the battery cooling assembly 150 includes a cooling volume assembly 160 which has an internal cavity or receiver into which a cooling fluid is inserted and can flow. In this embodiment, the cooling volume assembly is located near one end of the battery cells, as described below.

[0064] The cooling fluid can enter the assembly 160 through an inlet 162 and travel through the cavity of the cooling volume assembly 160, which includes asFigure 2B travels around all of the battery cells and then exits as a warmed fluid through outlet 164. In this embodiment, both the inlet 162 and the outlet 164 are oriented such that their openings are positioned inwardly from the cooling assembly, or along the direction of the axial length L toward the end 126. The cooling volume assembly 160 extends around and beyond the entire perimeter 130 of the battery cells, with portion 161 extending around the perimeter 130. As Figure 2A shown, the cooling volume assembly 160 is located near the end 128 of the battery cell. In this embodiment, the cooling volume assembly 160 is positioned flush with the end 128 of the battery cell and extends along a portion of the axial length L toward the battery cell end 126.

[0065] The battery cooling assembly according to the present disclosure achieves an improved uniform battery cell temperature distribution. The cooling volume assembly 160 cools around the entire battery cell perimeter 130 and cools across all of the modular battery cells in a well-distributed and uniform manner. Returning to reference Figure 2A , the battery cooling assembly 150 includes a cooling modular structure 170, which may alternatively be referred to herein as a modular structure skin, that is located near the conductive layer 102 in the areas around and between the battery cells.

[0066] Reference Figure 3A and Figure 3B show an alternative embodiment of a battery cooling assembly according to an aspect of the present disclosure. In this embodiment, different components of the cooling volume assembly are configured to allow these components to be joined during the manufacture of the cooling volume assembly. The battery cooling architecture 180 is used with a number of battery cells, and in Figure 3A only battery cells 175A, 175B, and 175C are shown.

[0067] The battery cooling architecture 180 includes a cooling volume assembly 182 having an inlet 183A and an outlet 183B and a modular structure skin 190. The modular structure skin 190 has a forging for each matching metal sleeve. As an example, the forging 191 is identified in Figure 3A . The forging 191 is located between adjacent sleeves.

[0068] In this embodiment, the cooling volume assembly 182 and the structure skin 190 are not joined to each other. Instead, each of the cooling volume assembly 182 and the structure skin 190 is directly joined to the battery cell housing, as shown in Figure 3A and Figure 3B . Specifically, the cooling volume assembly 182 is coupled to sleeves 184, which in this embodiment do not extend along the entire length of the battery cells. The locations where the cooling volume assembly 182 and the sleeves 184 are coupled or joined are the joining regions 186 and 188. AsFigure 3A As shown, the cooling volume assembly 182 has a bottom tray 185 that includes a bottom portion 187A and an upper portion 187B that are joined together at a junction region 186. In this embodiment, the inner ends of the bottom portion 187A and the upper portion 187B are oriented upward along the sleeve 184. The bottom tray 185 includes swaged portions 189A and 189B between adjacent sleeves. In this implementation, the swaged portions 189A and 189B are positioned such that their joined ends are oriented upward as shown.

[0069] The metal cooling volume assembly components can be joined or connected by one of several different methods, one of which is brazing. Alternative joining methods include fasteners with or without sealants, welding, adhesive bonding, fusion welding, friction stir welding, or other methods.

[0070] Turning to Figure 4A and Figure 4B , a side view and a bottom view, respectively, are shown of another embodiment of a battery cooling assembly in accordance with one aspect of the present disclosure for use with a battery.

[0071] In this embodiment, the battery 200 includes a number of battery cells 210, 212, 214, 216, 218, 220, 222, and 224, which are cylindrical in this embodiment. Each of these cells has a first end 226 and a second end 228 opposite the first end 226. Each cell also includes an axial length "L" extending from the first end 226 to the second end 228. Similar to the battery 100, a conductive layer 202 is coupled to the battery cells 210, 212, 214, 216, 218, 220, 222, and 224. Referring to Figure 4B , a perimeter 230 is defined around the battery cells 210, 212, 214, 216, 218, 220, 222, and 224, which is shown by a dashed line.

[0072] The battery cooling assembly 250 includes a cooling volume assembly 260 that has an internal cavity or receptacle into which a cooling fluid is inserted and can flow. In this embodiment, the cooling volume assembly 260 is located near the ends 228 of the battery cells (see Figure 4A ).

[0073] Cooling fluid can enter the assembly 260 through the inlet 262, travel around all the battery cells through the cavity of the assembly 260, and then leave as a warm fluid through the outlet 264. In this embodiment, both the inlet 262 and the outlet 264 are oriented such that their openings are positioned outwardly from the cooling assembly, or away from the end 228 along the direction of the axial length L. The cooling volume assembly 260 including the portion 261 extends around the perimeter 230 of the battery cells. In this embodiment, the cooling volume assembly 260 is positioned flush with the end 228 of the battery cells.

[0074] Reference Figure 4A , the battery cooling assembly 250 includes a modular structural skin 270 that is located near the conductive layer 202 in the area around and between the battery cells.

[0075] In this embodiment, the battery cooling assembly 250 includes a number of cooling sleeves, each cooling sleeve surrounding one of the battery cells in the battery cell stack. As Figure 4A shown, each cooling sleeve extends from a first end 126 to a second end 128 around each battery cell. In this embodiment, the cooling sleeve 280 surrounds the battery cell 210, the cooling sleeve 282 surrounds the battery cell 212, and the cooling sleeve 284 surrounds the battery cell 214. Additionally, as Figure 4B shown, additional cooling sleeves are positioned around the battery cells 216, 218, 220, 222, and 224.

[0076] Depending on the material, the axial length of the battery cell, and the thickness of the sleeve, the sleeve further improves the ability of the cooling volume assembly 250 to transfer heat to or from the battery cells and improves its thermal uniformity. Electrical isolation between battery cells and between battery cells and the cooling fluid can be achieved using several different methods. These methods include dielectric coatings, dielectric sleeves between the battery cells and the cooling volume, or other methods that can use different types of materials.

[0077] When cooling sleeves are added, due to the presence of the cooling sleeves, the amount of heat transfer area on the entire cylindrical surface of the battery cells increases. Compared with conventional cooling techniques, this increased heat transfer area results in improved battery cell temperature uniformity. Due to the increased heat transfer area and more open flow regions, the resulting cooling fluid pressure drop is lower than that of conventional cooling techniques, even for the same total battery cell heat load and for the same cooling fluid temperature rise.

[0078] Reference Figure 5A and Figure 5B , another embodiment of a battery cooling assembly according to an aspect of the present disclosure is shown. In this embodiment, different components of the cooling volume assembly are configured to allow these components to be joined during the manufacture of the cooling volume assembly. The battery cooling architecture 300 is used with a number of battery cells, inFigure 5A Only battery cells 340, 342, and 344 are shown.

[0079] The battery cooling architecture 300 includes a cooling volume assembly 302 having an inlet 304 and an outlet 306 and a modular structural skin 330. In this embodiment, the cooling volume assembly 302 and the structural skin 330 are coupled to each other via a metal sleeve 310, as shown. In this embodiment, the metal sleeve 310 extends along the entire length of the battery cells. The cooling volume assembly 302 and the structural skin 330 are coupled to the sleeve 310 via various coupling region areas 320, 322, and 324.

[0080] The metal cooling volume assembly components, including the sleeve and the structural skin, can be joined or coupled by several different methods, one of which is brazing. Alternative joining methods include fasteners with or without sealants, welding, adhesive bonding, fusion welding, friction stir welding, or other methods.

[0081] For the brazing method, there are several material choices. One possible material combination - aluminum for the sleeve, single-sided clad aluminum for the top tray of the cooling volume, double-sided clad aluminum for the bottom tray of the cooling volume, single-sided clad aluminum for the module structural skin, and single-sided clad aluminum for the inlet and outlet fittings. This design tolerates a wide range of material thicknesses. In different embodiments, the choice of material thickness depends on thermal, structural, and other performance and manufacturability requirements. As needed, the assembly fixtures required to braze the entire cooling volume assembly in a single step can be a base, side plates, a top plate, and some locking features. The base provides an appropriate bottom support structure. The side plates control the positions of the bottom tray of the cooling volume, the top tray of the cooling volume, and the structural skin. The top plate provides an appropriate top support structure. The design of the brazing fixtures also takes into account limiting how much heat is extracted from the brazing fixtures. These are common but worth mentioning practices.

[0082] Reference Figure 6 and Figure 7 show a side view and a bottom view, respectively, of another embodiment of a battery cooling assembly according to one aspect of the present disclosure. In this embodiment, the cooling volume architecture can control the positions of all the battery cells in the module by controlling the radial spacing and holding these battery cells in their controlled axial orientations with a minimum angular deviation. Thus, unlike conventional cooling architectures that require assembly fixtures to control the positions of the battery cells, the cooling volume architecture disclosed herein does not require any additional assembly fixtures to maintain the positions and stability of the battery cells.

[0083] The battery cooling assembly or architecture 350 includes a cooling volume assembly 360 having an inlet 362 and an outlet 364 for fluid to enter and leave the cooling volume assembly 360, respectively. The inlet 362 and the outlet 364 are oriented towards the modular structure skin 370 of the cooling volume assembly 360. The modular structure skin 370 has cooling characteristics.

[0084] In Figure 6 for simplicity of description, the battery cells are not shown. Sleeves 380, 382, and 384 extend between the cooling volume assembly 360 and the modular structure skin 370. The sleeves 380, 382, and 384 define channels 380A, 382A, and 384A therethrough, and each of the channels 380A, 382A, and 384A receives and surrounds an inserted battery cell. The cooling effect of the cooling fluid circulating within and through the cooling volume assembly 360 contributes to and improves the net cooling effect of the cooling sleeves 380, 382, and 384, which also contact the modular structure skin 370 and may be referred to as openings in the cooling volume assembly 360.

[0085] The sleeves 380, 382, and 384 provide cell axial (Z-axis) tilt control support or longitudinal alignment support for the battery cells. The sleeves 380, 382, and 384 have longitudinal axes 381, 383, and 385, respectively. The sleeves 380, 382, and 384 are oriented such that they maintain their respective battery cells aligned with the longitudinal axes 381, 383, and 385.

[0086] In addition, the sleeves of the battery cooling assembly or architecture 350 also provide lateral alignment support for the battery cells. Referring Figure 7 to, the battery cooling architecture 350 includes sleeves 380, 382, 384, 386, 388, 390, 392, and 394 extending upward from the cooling volume assembly 360. Each sleeve provides cell radial position support or lateral alignment support with respect to the X-axis and the Y-axis. For sleeve 384, the X-axis and the Y-axis are labeled as the horizontal or lateral axis 387 and the horizontal or lateral axis 389, respectively. In Figure 7 each axis 387 and 389 is shown for each sleeve of the cooling volume assembly 360.

[0087] As described in more detail below, generally speaking, the battery cooling architecture disclosed herein has several advantages. One advantage is improved cell temperature uniformity and lower cooling fluid pressure drop compared to conventional cooling techniques, even for the same total cell heat load and at the same cooling fluid temperature rise. Another advantage is that conventional cooling architectures rely on assembly fixtures to control the position of the battery during the assembly process, while the architecture disclosed herein controls the position of the battery without the aid of assembly fixtures. An additional advantage is that the disclosed architecture can improve thermal safety and does not require the addition of thermal mitigation agents such as foams used in conventional systems. The disclosed architecture separates the vent volume from the battery cell grid, and this is accomplished using metal rather than thermal mitigation materials such as foams used in conventional systems. These thermal mitigation agents generally do not contribute significant structural benefits and make the assembly of the module more complex. Yet another advantage is that the current collector, alternatively referred to as such, will be cooled more directly and be able to operate at a lower temperature, which will have a positive impact on its operating life and will also allow the current collector to be designed as a thinner metal, resulting in mass and cost savings. Additionally, the architecture disclosed herein will be able to operate at a higher peak current than conventional systems. Another advantage is that the cooling volume components have a honeycomb structure, which, in combination with the battery cells inside the sleeve (which effectively makes them solid structural elements), results in a substantially solid structural module assembly. Yet another advantage is that the battery cooling architecture design also has the flexibility to easily scale its size to any desired uniform or non-uniform cell-to-cell spacing.

[0088] The present invention allows for the connection of the entire assembly of the cooling volume components in a single step. This ability is important because the single-step process results in easy assembly of the system to achieve the advantages disclosed herein. Additionally, the manufacturing methods disclosed herein have the advantage of significantly reducing the complexity of the module assembly process because they do not require the use of assembly fixtures to position the battery cells. Furthermore, the design of the battery cooling architecture enables good position control of the battery cells. This results in a reduction in the overall manufacturing cost of the module assembly line and the operating expenses of running the production line.

[0089] The battery cooling architecture according to aspects of the present disclosure improves thermal safety because it does not require the addition of thermal mitigation agents used in conventional systems. These thermal mitigation agents generally do not contribute major structural benefits and also make the assembly of the module more complex. First, the battery cooling architecture disclosed herein does not require such agents because, compared to conventional systems that use thermal mitigation agents to prevent hot gases from entering the cell grid, this architecture prevents hot thermal runaway gases from entering the battery cell matrix. Second, the battery cooling architecture disclosed herein has the ability to better absorb heat from a runaway battery by utilizing a larger portion of the thermal mass of the battery module. In one aspect, this is due to the cooling volume having a full area coverage of the cell grid. In another aspect, this is also due to the cooling volume having highly thermally conductive metal extending across all the battery cells, which are coupled by the cooling volume having thermal contact with a cylindrical region surrounding all the battery cells in the cell grid. Additionally, even at high temperatures where the thermal interface material may start to lose its thermal conductivity characteristics, any battery cell that enters thermal runaway remains in good thermal connection. This is because the cooling volume metal is able to maintain a tight clearance with the thermal runaway battery. In contrast, conventional systems cannot keep the thermal runaway battery in good thermal connection to their cooling devices because their thermal interface materials lose their ability to effectively transfer heat at high temperatures. Furthermore, the thermal runaway battery cannot maintain a tight clearance with its cooling device and thus loses the ability to dissipate heat and distribute heat to the rest of the cell grid thermal mass with the help of the cooling device.

[0090] Another aspect of the battery cooling architecture disclosed herein is the cooling of one or more conductive layers. In this aspect, one or more conductive layers have a thermal connection directly coupled to the cooling volume assembly. This thermal connection has the significant effect of improving the temperature uniformity of the conductive layer and keeping it operating at a lower temperature. This prevents the conductive layer from dissipating heat mainly through its electrical connection to the battery cell, which also prevents the battery cell from having hot spots near those connections to the conductive layer. The conductive layer can operate at a lower temperature, which increases its operating life and allows the conductive layer to be thinner, resulting in reduced mass and increased cost savings. Additionally, due to the low thermal mass of the conductive layer and its ineffective cooling, the conductive layer is able to operate at a higher peak current relative to conventional systems.

[0091] Another aspect of the battery cooling architecture disclosed herein is the structural aspect and support. The cooling volume assembly is designed in a honeycomb structure. This structure is formed by cylindrical sleeves on each battery cell, which are connected to two connected metal layers of the cooling volume assembly at one axial end and to another metal layer skin at the opposite axial end. Additionally, the battery cells inside the sleeves provide further structural stiffness to the cylindrical sleeves, resulting in the sleeve-cell assembly being effectively a solid structural element. The only relative movement of the cooling volume assembly with respect to the battery cells is due to the deformation of the skin near the axial ends of the sleeves. Since the skins are separated by a large gap approximately equal to the axial length of the cells, the module structure assembly stiffness is quite large due to the large moment of inertia provided by the skins and the sleeves connecting the skins. Thus, the resulting battery cooling architecture provides a solid structural module assembly together with the battery cells. This module assembly design can be used to implement a structural battery pack that can increase the structural integrity of the vehicle frame.

[0092] The battery cooling architecture disclosed herein allows for the addition of metal pieces that strategically connect the cooling volume cell sleeves, such that the cooling volume cell sleeves can more effectively transfer heat from a hot thermally runaway battery cell to other battery cells that are not in close proximity to the hot thermally runaway battery cell. With the proper sizing of these elements, the heat absorption of the rest of the battery module thermal mass from the thermally runaway battery cell can be improved.

[0093] It should be understood that the foregoing advantages, benefits, and features of the described battery cooling architecture can be achieved in different variants of the battery cooling architecture. The following architecture variants result in similar solutions, each variant having its own advantages. Variants contemplated according to aspects of the present disclosure include the following embodiments and combinations of features from different embodiments.

[0094] Turning to Figure 8 and Figure 9 , side and bottom views of another embodiment of a battery cooling assembly according to an aspect of the present disclosure for use with a battery are shown. In different embodiments, the size, shape, or configuration of the battery cells can vary with respect to the previously described embodiments. For example, the battery cells and any corresponding sleeves for the battery cells can have a shape or configuration different from the cylindrical shape or configuration, such as a prismatic configuration or a pouch cell. In this embodiment, the battery 400 has battery cells 410, 412, and 414, which have a first end 426 connected to a conductive layer 402 and an opposite second end 428 spaced apart from the first end 426 along an axial length "L".

[0095] In this embodiment, the battery cooling architecture 450 includes a cooling volume component 460 having a receiver for a cooling fluid and an inlet 462 and an outlet 464 through which the cooling fluid flows. As shown, there are three sleeves 480, 482, and 484 located between the cooling volume component 460 and the module structure skin 470, which is adjacent to and in contact with the conductive layer 402. Figure 9 The pouch shapes of the battery cells 410, 412, and 414 and their corresponding sleeves 480, 482, and 484 are shown. The battery cells 410, 412, and 414 together have a perimeter 430, and a portion 461 of the cooling volume component 460 is positioned around the perimeter.

[0096] Another set of alternative embodiments relates to the location of the battery cell thermal event vents. In different embodiments, the battery cell vent locations can vary, as Figures 10 to 13 shown.

[0097] In one implementation, referring to Figure 10 , the thermal vent side of the battery cells is on the same end of the battery cells as the cooling volume component. As shown, this end of the battery cells is opposite the positive terminals and the conductive layer of the battery cells. Specifically, the battery cells 510, 512, and 514 are connected to the conductive layer 502 at one end, and their opposite ends are the thermal vent sides of the cells 510, 512, and 514. The battery cooling architecture 550 includes a cooling volume component 560 having an inlet 562 and an outlet 564. The cooling volume component 560 is located at the end of the sleeve (only sleeve 580 is labeled for simplicity) and the cells 510, 512, and 514 opposite the module structure skin 570, which is adjacent to the conductive layer 502.

[0098] In another implementation, referring to Figure 11 , the thermal vent side of the battery cells is on the same end of the battery cells as the positive terminals and the conductive layer of the cells, which is the end opposite the location of the cooling volume component. Specifically, the positive terminals of the battery cells 610, 612, and 614 are connected to the conductive layer 602. In this embodiment, those ends of the battery cells are the thermal vent sides 640 of the cells 610, 612, and 614. The battery cooling architecture 650 includes a cooling volume component 660 having an inlet 662 and an outlet 664. The cooling volume component 660 is located at the end of the sleeve 680 and the cells 610, 612, and 614 opposite the module structure skin 670, which is adjacent to the conductive layer 602.

[0099] In another implementation, referring to Figure 12, the cell vent position 740 is on the same end of the battery cells 710, 712, and 714 as the cooling volume assembly 760, the cell positive terminals, and the conductive layer 702. The module structure skin 770 is located at the opposite end of the battery cells 710, 712, and 714 and the sleeve 780.

[0100] In yet another implementation, refer to Figure 13 , the cell vent position 840 is on the opposite side of the cell positive terminals, the cooling volume assembly 860, and the conductive layer 802 of the battery cells 810, 812, and 814. The module structure skin 870 is located at the same end of the battery cells 810, 812, and 814 and the sleeve 880 as the cell vent position 840.

[0101] Another variation of the battery cooling architecture embodiments disclosed herein relates to the specific orientation of the battery cells. In some embodiments, the battery cells are vertically oriented and have a downward-facing thermal event vent. In this arrangement, the orientation of the electric vehicle directs the venting away from the cab. However, alternative architecture designs may include vertically oriented battery cells with upward venting or even horizontally oriented battery cells with venting to either side, which may be necessary for reasons of battery module packaging within the battery pack.

[0102] Yet another variation of the battery cooling architecture embodiments disclosed herein relates to the position of the cooling volume assembly along the axial length of the battery cells. Before turning to Figures 14 to 18 (each of these figures shows a cooling volume module architecture with a cooling volume assembly at different cell axial positions), refer to Figure 10 . In Figure 10 , the cooling volume assembly 560 is located near the bottom ends of the battery cells 510, 512, and 514, and the thermal vent sides 540 of the battery cells 510, 512, and 514 are also located at these bottom ends. Specifically, the outer surface of the cooling volume assembly is flush with the lower or second end of the battery cells. This configuration enables the cooling volume assembly 560 to prevent overheating of the battery cell grid by acting as a thermal shield for the thermal event gas.

[0103] Now refer to Figures 14 to 18 , which shows different embodiments illustrating other possible positions and orientations of the cooling volume assembly. Turning to Figure 14, the conductive layer 902 is located at one end of the battery cell 910, and each of these battery cells is surrounded by a sleeve 980. Adjacent to the conductive layer 902 is the module structure skin 970, and both of them are located at the end of the battery cell 910 that is the thermal ventilation side 940 of the cell 910. The cooling volume assembly 960 is located at the end of the battery cell 910 opposite to the conductive layer 902 and the module structure skin 970. In this orientation, the cooling volume assembly 960 is located at the upper end of the vertically oriented battery cell 810. The inlet 962 and outlet 964 of the cooling volume assembly 960 are oriented downward along the direction of the battery cell 910.

[0104] Reference Figure 15 , the conductive layer 1002 is located at one end (such as the upper end) of the battery cell 1010, and these battery cells are surrounded by a sleeve 1080. The module structure skin 1070 is also positioned adjacent to the conductive layer 1002. In this embodiment, the cooling volume assembly 1060 is oriented such that the inlet 1062 and outlet 1064 point upward. In addition, the cooling volume assembly 1060 is located at an intermediate position 1065 along the battery cell 1010, and this intermediate position is between the opposite ends 1026 and 1028 of the battery cell 1010. In other embodiments, the cooling volume assembly 1060 can be located at other intermediate positions 1065 between the battery cell ends. For example, in Figure 16 , the cooling volume assembly 1160 has been moved along the battery cell 1010 in the direction of arrow "A" to another intermediate position 1166, and this other intermediate position is different from Figure 15 the intermediate position 1065 shown in, and is located between the opposite ends 1126 and 1128. The intermediate position 1166 is the axial center position along the length of the battery cell 1110.

[0105] Reference Figure 17 , the battery cell 1210 has opposite ends 1226 and 1228. The cooling volume assembly 1260 has been moved along the direction of arrow "B" to an extended position 1267 relative to the end 1228 of the battery cell 1210. In this extended position 1267, a first part of the cooling volume assembly 1260 is adjacent to and overlaps the battery cell 1210, and another part or second part of the cooling volume assembly 1260 extends beyond the end 1228 of the battery cell.

[0106] Reference Figure 18, the battery cell 1310 has opposite ends 1326 and 1328, similar to the previously described battery cell. In this embodiment, the cooling volume assembly 1360 has moved to an extended position 1368 relative to the end 1328 of the battery 1310 in the direction of arrow "C". In this extended position 1368, the cooling volume assembly 1360 extends completely beyond the end 1328 of the battery cell 1310.

[0107] Another variation of the battery cooling architecture is the position or location of one or more conductive layers. In one implementation, the battery cooling architecture has a conductive layer on the same side as the cooling volume assembly (see Figure 13 ). As Figure 13 shows, the conductive layer 802 is placed directly on the cooling volume assembly 860. In another implementation, the battery cooling architecture has conductive layers at opposite ends of the cooling volume assembly (see Figure 11 ). Although placing the conductive layer directly on the cooling volume assembly ensures better temperature control of the conductive layer, placing the conductive layer at the opposite ends also effectively controls its temperature. Therefore, the position of the conductive layer is determined based on performance, design, manufacturing, or other technical reasons.

[0108] In different embodiments, another feature that can vary is the orientation and number of cooling volume inlets and outlets for the cooling volume assembly. As described above, the orientation of the inlet fitting and the outlet fitting can face down or face up. Additionally, the number of inlet fittings and the number of outlet fittings can also vary, particularly independently of each other. The orientation and number of the fittings are determined based on cooling tube routing, packaging, and other technical requirements.

[0109] In other embodiments, another feature that can vary is the inclusion or addition of a high-temperature thermal shield. Referring to Figure 19 , a number of battery cells 1410 are surrounded by a sleeve 1480 and have a cooling volume assembly 1460 at one end and a module structure skin 1470 and a conductive layer 1402 at the other end. The thermally ventilated side 1440 of the cell 1410 is at the same end as the cooling volume assembly 1460.

[0110] In this embodiment, a high-temperature material as the thermal shield 1490 is provided adjacent to the cooling volume assembly 1460 and the end 1428 of the battery cell 1410. As Figure 19 shows, the high-temperature thermal shield 1490 shields the exposed battery surface facing the thermally ventilated area. The material of the thermal shield 1490 allows the battery cell 1410 that enters thermal runaway to exhaust with minimal obstruction, but remains intact to protect the rest of the battery cell grid from high-temperature gases.

[0111] In Figures 20 to 21An exemplary manner of including a thermal shield in a cooling volume component according to aspects of the present disclosure is shown. As shown, the battery cooling architecture 1600 includes a cooling volume component 1610 having an inlet 1612 and an outlet 1614, and a module structural skin 1630. Each of the cooling volume component 1610 and the module structural skin 1630 is coupled to a sleeve 1620 at a plurality of locations, including connection regions 1622, 1624, and 1626. In Figure 20 several battery cells 1640, 1642, and 1644 are shown.

[0112] In this embodiment, the battery cooling architecture 1600 includes an additional tray 1652, which is a thermal shield support tray 1652. The tray 1652 is located below the cooling volume bottom tray, which has a number of shaped portions for welding the tray within certain areas of the battery grid around the cooling volume perimeter but also in the gap spaces left between the metal sleeves. In one embodiment, the high-temperature thermal shield 1650 used with the cooling volume component 1610 can be made of individual circular thermal shield discs. Alternatively, the high-temperature thermal shield 1650 can be made of a single piece of material having cutouts only in the areas required for welding the thermal shield support tray 1652. In one embodiment, the cooling volume bottom tray has a shaped perimeter portion for welding to the cooling volume perimeter. In this implementation, the thermal shield is made of a single piece of material.

[0113] In other embodiments, the battery cooling architecture includes heat transfer elements located between the battery cells. These heat transfer elements may be referred to as far-cell neighbor heat transfer elements. In one implementation, each heat transfer element is a metal piece thermally connected from each cell sleeve to its next row of neighbors, as Figures 22 to 23 shown. Figure 22 is a side view of this embodiment of the battery cooling architecture, and Figure 23 is a cross-sectional top view taken along line “D-D” in Figure 22 .

[0114] As shown, the battery cooling architecture includes a number of heat transfer elements 1585 that serve as thermal event safety enhancement measures. The heat transfer elements 1585 allow for a more direct heat transfer from a hot thermal runaway battery cell to at least one remote neighbor battery cell rather than an adjacent battery cell, which reduces the heat transferred to the adjacent battery cell. By appropriately sizing the heat transfer elements 1585, the heat generated by a battery cell in thermal runaway can be more evenly shared across the entire battery cell grid. This approach reduces the impact of a thermal runaway battery cell on its adjacent battery cells because each individual battery cell receives a lower heat input and results in a lower temperature during a battery cell thermal event. The lower temperature applied to adjacent battery cells means that these battery cells will have a greater safety margin against entering thermal runaway. In some cases, the design of the heat transfer elements includes a thermal fusion to prevent the transfer of very high thermal energy.

[0115] As Figure 22 and Figure 23 shown, many of these features are the same as the previous battery cooling architecture embodiments described above, including the conductive layer 1502, the module structure skin 1570, and the cooling volume system 1560 having an inlet 1562 and an outlet 1564. A number of battery cells 1510 are provided, each battery cell being surrounded by a sleeve 1580.

[0116] In Figure 22 this, the heat transfer element 1585 is shown in the gap between adjacent sleeves. Referring Figure 23 to, one of the heat transfer elements 1585 is described in more detail, noting that this description applies to the other heat transfer elements 1585. Sleeves 1580 and 1582 are positioned around battery cells 1510 and 1512 respectively. The heat transfer element 1585 has opposite ends 1586 and 1587 that are fused to sleeves 1580 and 1582 respectively. Heat can be transferred along element 1585 between cooling sleeve 1580 and cooling sleeve 1582. As shown, the heat transfer element 1585 is not connected or coupled to the sleeve 1584 for battery cell 1514, which is closer to the two battery cells than the distance between battery cells 1510 and 1512 from each other. In this embodiment, cooling sleeve 1582 is separated from cooling sleeve 1580 by a first distance "d1", cooling sleeve 1582 is separated from cooling sleeve 1584 by a second distance "d2", and cooling sleeve 1580 is separated from cooling sleeve 1584 by a third distance "d3". The first distance "d1" is greater than the second distance "d2" and greater than the third distance "d3".

[0117] Another variation in different embodiments relates to the internal structure of the cooling volume. Generally speaking, the cooling volume assembly does not require an internal structure to perform its primary function of cooling the battery cell grid. However, one or more internal elements can be added to the cooling volume assembly to enhance its cooling characteristics as well as its structural and pressure tolerance capabilities, both internal and external. For example, an internal fin structure can enhance the cooling capacity of the cooling volume assembly. Additionally, internal structural elements can be added to the cooling volume assembly to allow it to withstand higher internal pressures from the hydraulic system and to improve its structural integrity against external loads. These structural elements can be one or more separate pieces mechanically coupled to the inner wall of the cooling volume assembly. Alternatively, these structural elements can be additional shapes or configurations formed in the walls of the cooling volume assembly that create additional mechanical couplings within the cooling volume. In some implementations, these internal structural elements can be added for their structural benefits and are also designed to enhance the heat transfer capabilities of the cooling volume.

[0118] Another variation in different embodiments is whether to use a cell-to-sleeve adhesive. In one implementation, the battery cells are adhered to the cooling volume assembly. Alternatively, the battery cells can also be assembled into the cooling volume assembly without any adhesive. Adhering the battery cells to the cooling volume assembly improves the heat transfer between the battery cells and the cooling volume assembly. Additionally, the overall structural integrity of the assembly is also enhanced. In the alternative, not adhering the battery cells to the cooling volume assembly simplifies the manufacturing process and makes it easier to disassemble the cooling volume assembly for possible battery pack repairs or recycling of the cooling volume assembly.

[0119] In other embodiments, the shape of the battery cell sleeve can vary. In some embodiments, the shape of the sleeve is cylindrical with a circular cross-section. In other embodiments, different sleeve cross-sectional shapes can be used, which can improve the structural aspects of the cooling volume assembly in different arrangements and configurations.

[0120] Furthermore, in various embodiments, the structure of the battery cell grid can vary in terms of the layout of the battery cells, the total number of battery cells, the rows and / or columns of the battery cells, and the spacing between adjacent battery cells. For example, Figure 2B and Figure 4B shows a view of a battery cell grid with a total of eight battery cells arranged in three rows and five columns, noting that the battery cells in adjacent columns overlap each other. Additionally, Figure 9 shows a view of a battery cell grid with a total of three battery cells arranged in a single row. Additionally, Figure 23A view of a battery cell grid with a total of 20 battery cells arranged in five rows and eight columns is shown, with these eight columns overlapping adjacent columns. The aspects disclosed herein relate to battery cell grids having various arrangements and numbers of battery cells and are not limited to the specific battery cell grid arrangement disclosed herein. These aspects relate to battery cell grids that extend as much as possible row-by-row and / or column-by-column, including X rows and Y columns of battery cells.

[0121] In different embodiments, the cooling fluid used in the cooling volume assembly can also vary. There are a variety of cooling fluids that can be used in the cooling volume assembly. One fluid is an ethylene glycol / water mixture. Other fluids can include the use of dielectric fluids, which can enable different variants of the cooling volume architecture without the need for electrical isolation between the cells and the coolant volume, where all cells share the same electrical potential.

[0122] In other embodiments, the electrical connection of the cooling volume assembly can vary. By being electrically connected to the cell cylinder, the cooling volume assembly can be used as part of the electrical connection, which allows it to be the common negative side of a set of cells in parallel. A conductive layer is positioned for connection to the positive terminal of the cell. The electrical connection to the rest of the electrical chain can be made on the positive side to the current collector layer and then on the negative side to the cooling volume assembly. Alternatively, by electrically connecting the negative portion of the current collector layer to the cooling volume, the current collector layer can serve both the positive connection and the negative connection.

[0123] There are several variants for manufacturing the cooling volume disclosed herein. Referring to Figure 24A 、 Figure 24B 、 Figure 25A 、 Figure 25B 、 Figure 26A and Figure 26B , different variants of the ends of the cooling volume of the battery cooling architecture are shown.

[0124] Turning first to Figure 24A and Figure 24B , the battery cooling architecture 1700 includes a cooling volume assembly 1710 and a modular structure skin 1730, which are connected to each other via a metal sleeve 1714 that extends along the entire length of the battery cells. The positions where the cooling volume assembly 1710 and the modular structure skin 1730 are joined or linked to the sleeve 1714 are shown as joining regions 1716, 1718, and 1720.

[0125] The cooling volume assembly 1710 has a bottom tray 1715 that includes a bottom portion 1717A and an upper portion 1717B that are joined together at a connection portion region 1716. In this embodiment, the inner ends of the bottom portion 1717A and the upper portion 1717B are oriented towards each other along the sleeve 1714. The bottom tray 1715 includes forged portions 1719A and 1719B. The forged portion 1719B of the bottom tray 1715 faces upward, rather than downward as Figure 3A shown. In this embodiment, the bottom portion 1717B has a flange portion 1740 that extends outwardly and is joined to a flange portion 1742 that extends outwardly of the upper portion 1717A.

[0126] Turning Figure 25A and Figure 25B , the battery cooling architecture 1800 includes a cooling volume assembly 1810 that has a bottom tray 1815 that has a bottom portion 1817A and an upper portion 1817B that are joined together. In this embodiment, the bottom portion 1817A has a curved configuration with a flange portion 1840, and the upper portion 1817B has a curved configuration with a flange portion 1842. As Figure 25A shown, the flange portions 1840 and 1842 are positioned such that they overlap each other, which provides a location where they can be joined. In this implementation, there are no outwardly extending flanges that can be joined together. Thus, the cooling volume is welded peripherally, not relying on the horizontal plane of a welded tray, but rather on the vertical plane of the forged perimeter of the upper portion of the tray 1815 or tray 1817B and the bottom portion or tray 1817A. In alternative embodiments, the specific shape and order (such as portion 1840 inside portion 1842) can vary in the vertical plane, and any combination of the inner and outer surfaces of the forged perimeter can be used.

[0127] Moving on to Figure 26A and Figure 26B , the battery cooling architecture 1900 includes a cooling volume assembly 1910 that has a bottom tray 1915 that has a bottom portion 1917A and an upper portion 1917B that are joined together. In this embodiment, the bottom portion 1917A has a curved configuration with a connection portion 1940, and the upper portion 1917B has a curved configuration with a connection portion 1942. As Figure 26AAs shown, flange portions 1940 and 1942 are positioned such that their ends are close to each other. In this implementation, there are no outwardly extending flanges that can be joined together. Thus, the cooling volume is welded peripherally, not relying on the horizontal plane of the welding tray, but on the coupler 1950 that wraps around the peripheries of flange portions 1940 and 1942. The coupler 1950 is welded to the outer regions of the forged peripheries of both the bottom portion 1917A and the upper portion 1917B of the tray 1915.

[0128] Another variant feature of the battery cooling architecture design disclosed herein is the shape of the module structure skin. Turning to Figure 27A and Figure 27B , the battery cooling architecture 2000 includes a cooling volume assembly 2010 and a module structure skin 2030. In this implementation, instead of being forged as the module structure skin 190 as shown in Figure 3A , the module structure skin 2030 is a flat piece having a number of circular cutouts 2032 that match the upper end of the sleeve 2014. Each of the cutouts 2032 receives over the sleeve 2014. Instead of relying on the larger surface area of the forging of the module structure skin 190, the coupling joints 2020 in this implementation utilize the area provided by the thickness of the module structure skin 2030 in combination with the circumference of the sleeve 2014. By using less material, the manufacturing cost is reduced.

[0129] In different applications, the battery cooling architecture disclosed herein can be used with battery packs for electric vehicles, energy storage, electric vertical takeoff and landing aircraft, and other electrical devices and equipment.

[0130] Although the invention has been illustrated and described in detail with reference to its specific embodiments, the invention is not intended to be limited to the details shown, as it is apparent that various modifications and structural changes can be made therein without departing from the scope of the invention and within the scope and range of equivalents of the claims. Additionally, various features from one embodiment can be incorporated into another embodiment. Therefore, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the present disclosure as set forth in the appended claims.

[0131] Similarly, the present invention is intended to cover modifications and variations of the present invention that fall within the scope of the appended claims and their equivalents. For example, it should be understood that terms such as "left", "right", "top", "bottom", "front", "back", "side", "height", "length", "width", "upper", "lower", "inner", "outer", "inside", "outside" that may be used herein merely describe reference points and do not limit the present invention to any particular orientation or configuration. In addition, the term "exemplary" is used herein to describe an example or illustration. Any embodiment described herein as exemplary should not be construed as a preferred or advantageous embodiment, but rather as an example or illustration of a possible embodiment of the present invention.

[0132] Finally, as used herein, the term "comprising" and its derivatives (such as "including", etc.) should not be understood in an exclusive sense, i.e., these terms should not be construed as precluding the possibility that the things described and defined may include other elements, steps, etc. At the same time, as used herein, the term "about" and its cognates (such as "approximately", etc.) should be understood to indicate a value that is very close to the value accompanying the foregoing term. That is, a deviation within a reasonable limit from the exact value should be accepted, because those skilled in the art will understand that such a deviation from the indicated value is inevitable due to measurement inaccuracies, etc. This also applies to the terms "circa" and "approximate" and "substantially".

Claims

1. A battery cooling system for use with one or more battery cells, comprising: A cooling volume component that defines an internal chamber, the cooling volume component including an inlet and an outlet, each of the inlet and the outlet being in fluid communication with the internal chamber; and A cooling modular structure spaced apart from the cooling volume component, wherein the cooling volume component and the cooling modular structure cool the one or more battery cells, and fluid travels through the inlet, the internal chamber, and the outlet of the cooling volume component.

2. The battery cooling system according to claim 1, wherein a conductive layer is connected to the one or more battery cells, and the cooling modular structure is placed in contact with the conductive layer.

3. The battery cooling system according to claim 1, wherein each of the one or more battery cells includes a first end and a second end opposite the first end, a conductive layer is connected to the first end of each battery cell, and the cooling modular structure is placed in contact with the second end of each battery cell.

4. The battery cooling system according to claim 1, wherein the one or more battery cells define a perimeter therearound, and the cooling volume component extends over the entire extent of the perimeter.

5. The battery cooling system according to claim 1, wherein each of the one or more battery cells includes a first end and a second end opposite the first end, and each battery cell includes an axial length extending between the first end and the second end.

6. The battery cooling system according to claim 5, wherein one of the first end and the second end is a thermally ventilated side of each battery cell.

7. The battery cooling system according to claim 5, wherein the cooling volume component is positioned adjacent the second end of each battery cell such that an outer surface of the cooling volume component is flush with the second end of each battery cell.

8. The battery cooling system according to claim 5, wherein the cooling volume component is positioned at an intermediate position along the axial length of each battery cell, and the intermediate position is between the first end and the second end.

9. The battery cooling system according to claim 5, wherein the cooling volume component is positioned in an extended position relative to each battery cell, a first portion of the cooling volume component is adjacent an outer surface of each battery cell, and a second portion of the cooling volume component extends beyond the second end of each battery cell.

10. The battery cooling system according to claim 5, wherein the cooling volume component is positioned in an extended position relative to each battery cell, and the cooling volume component extends completely beyond the second end of each battery cell.

11. The battery cooling system according to claim 1, further comprising: A cooling sleeve, the cooling sleeve being located between the cooling volume component and the cooling modular structure, the cooling sleeve defining a passage therethrough, the passage receiving therein one of the one or more battery cells.

12. The battery cooling system according to claim 1, further comprising: A first cooling sleeve, the first cooling sleeve being located between the cooling volume component and the cooling modular structure, the first cooling sleeve defining a first passage therethrough, the first passage receiving therein a first battery cell; A second cooling sleeve, the second cooling sleeve being located between the cooling volume component and the cooling modular structure, the second cooling sleeve defining a second passage therethrough, the second passage receiving therein a second battery cell; and A heat transfer element, the heat transfer element being coupled to the first cooling sleeve and the second cooling sleeve.

13. The battery cooling system according to claim 12, further comprising: A third cooling sleeve, the third cooling sleeve being located between the cooling volume component and the cooling modular structure, the third cooling sleeve defining a third passage therethrough, the third passage receiving therein a third battery cell, wherein the first cooling sleeve is spaced apart from the second cooling sleeve by a first distance, the first cooling sleeve is spaced apart from the third cooling sleeve by a second distance, and the second cooling sleeve is spaced apart from the third cooling sleeve by a third distance, the first distance being greater than each of the second distance and the third distance.

14. A battery cooling system for use with a battery cell having a conductive layer coupled thereto, the battery cooling system comprising: A cooling volume component, the cooling volume component defining an internal chamber, the cooling volume component including an inlet and an outlet, each of the inlet and the outlet being in fluid communication with the internal chamber, and a cooling fluid traveling through the inlet, the internal chamber, and the outlet of the cooling volume component; A cooling modular structure, the cooling modular structure being spaced apart from the cooling volume component; And A cooling sleeve, the cooling sleeve being connected to the cooling volume component and the cooling modular structure and being located between the cooling volume component and the cooling modular structure, the cooling sleeve defining a passage in which one of the battery cells is located, wherein the cooling volume component, the cooling modular structure, and the cooling sleeve cool the battery cell.

15. The battery cooling system according to claim 14, wherein each of the battery cells includes a first end and a second end opposite the first end, each battery cell including an axial length extending between the first end and the second end.

16. The battery cooling system according to claim 15, wherein the cooling volume component is positioned adjacent to the second end of each battery cell such that an outer surface of the cooling volume component is flush with the second end of each battery cell.

17. The battery cooling system according to claim 15, wherein the cooling volume component is positioned at an intermediate position along the axial length of each battery cell, and the intermediate position is between the first end and the second end.

18. The battery cooling system according to claim 15, wherein the cooling volume component is positioned in an extended position relative to each battery cell, a first portion of the cooling volume component is adjacent to the outer surface of each battery cell, and a second portion of the cooling volume component extends beyond the second end of each battery cell.

19. A battery cooling system for use with battery cells in a battery cell grid, the battery cooling system comprising: a cooling volume component that defines an internal chamber, the cooling volume component including an inlet and an outlet, each of the inlet and the outlet being in fluid communication with the internal chamber; a first cooling sleeve that is capable of engaging with the cooling volume component, the first cooling sleeve defining a first channel in which a first battery cell is located; a second cooling sleeve that is capable of engaging with the cooling volume component, the second cooling sleeve defining a second channel in which a second battery cell is located; and a heat transfer element coupled to the first cooling sleeve and the second cooling sleeve, wherein the heat transfer element is capable of transferring thermal energy between the first cooling sleeve and the second cooling sleeve.

20. The battery cooling system according to claim 19, further comprising: a third cooling sleeve that is capable of engaging with the cooling volume component, the third cooling sleeve defining a third channel in which a third battery cell is located, wherein the first cooling sleeve is spaced apart from the second cooling sleeve by a first distance, the first cooling sleeve is spaced apart from the third cooling sleeve by a second distance, and the second cooling sleeve is spaced apart from the third cooling sleeve by a third distance, the first distance being greater than each of the second distance and the third distance.

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