Battery tower

Abstract

According to one aspect of the present invention, there is provided a battery tower including a plurality of unit cases stacked one above the other. Each unit housing defines at least one unit compartment and a cooling conduit thermally coupled to the at least one unit compartment. The battery tower also includes a cooling duct connector attached to two adjacent stacked cell housings to fluidly couple the cooling ducts of the two adjacent stacked cell housings.

Description

Technical Field

[0001] The present invention relates to a battery tower comprising a stack of cell housings and a connector that fluidly connects cooling pipes of adjacent stacked cell housings, and the present invention relates to a battery pack comprising a plurality of such battery towers. Background Technology

[0002] The growing focus on replacing fossil fuels with renewable energy has led to the development of many new electrical products. For example, cars, trains, heating systems, and household appliances can all be powered by electricity. In some cases, it may be advantageous for electrical products to be powered at least partially by electrochemical batteries. Batteries typically consist of multiple cells that are electrically connected to each other in some way. While batteries offer many advantages, several technological challenges remain.

[0003] For example, charging and discharging battery cells can cause temperature variations within the cells. Over time, these temperature fluctuations can lead to changes in resistance, loss of charging or discharging performance, and mechanical stress, potentially harming the cell's lifespan. Therefore, managing the temperature of cells in use is an important consideration.

[0004] Furthermore, battery cells typically contain chemicals and therefore require protection from damage for safe use. Finally, batteries can be used in space-constrained applications, and space-efficient battery cell layouts and temperature management solutions can be advantageous in many situations.

[0005] It was in this context that the present invention was developed. Summary of the Invention

[0006] According to one aspect of the invention, a battery tower is provided, comprising a plurality of unit housings stacked one on top of the other. Each unit housing defines at least one unit compartment and a cooling conduit thermally connected to the at least one unit compartment. The battery tower further includes a cooling conduit connector attached to two adjacent stacked unit housings to fluidly connect the cooling conduits of the two adjacent stacked unit housings.

[0007] In use, the cooling conduits preferably include a cooling fluid. Therefore, the battery tower can be referred to as a fluid-cooled battery tower. The cooling fluid can include a cooling liquid. For example, the cooling fluid can include water or a water-based cooling liquid. Thus, the battery tower is advantageously configured to both hold (i.e., fix) one or more battery cells in use and provide cooling to the battery cells held by the cell housings. Therefore, the battery tower promotes efficient cooling and provides an efficient means of supporting and organizing multiple cells. Additionally, the cell housings, particularly the cell compartments, can help protect the cells within the battery tower.

[0008] Battery towers facilitate temperature management of the cells held within the cell compartments of the respective cell housings. In particular, in advantageous examples, the battery tower comprises a cell housing characterized by cell compartments and integrated cooling conduits. Therefore, cooling is provided at least in part by the same components that hold the cells in place. Thus, in some examples, the battery tower may be referred to as a bulk-cooled battery tower.

[0009] While this document primarily refers to cooling units within the cell housing, it should be understood that the apparatus described herein is primarily configured to facilitate heat transfer between the cells and the cooling conduits (i.e., the cooling fluid in the cooling conduits during use) of the corresponding cell housing. Therefore, the battery tower described herein facilitates temperature management of the cells within the cell compartments, i.e., cooling and heating these cells. While cell cooling is described in more detail throughout, as another example, in use, the cells held within the cell compartments can also be heated by supplying a fluid in the cooling conduits at a temperature higher than that of the cells within the cell compartments. In such an example, the heating fluid in the cooling conduits can supply heat to the cell housing and, in particular, to the cell compartments via conduction through the cell housing, thereby supplying heat to the corresponding cells within the cell compartments. Therefore, references to cooling conduits herein can be understood to refer more generally to fluid conduits, and references to cooling fluid herein can be understood to refer more generally to fluids and not just cooling fluids. Facilities for heating and cooling the cells can facilitate maintaining the cell temperature within safe and / or optimal temperature ranges, thereby improving cell performance and / or extending their lifespan.

[0010] Thermal connections between the cooling conduits of one or more unit compartments and the unit housing facilitate the transfer of thermal energy (i.e., heat) between the cooling conduits of one or more unit compartments and the corresponding unit housing. The unit compartments of the unit housing can be directly thermally connected to the cooling conduits, for example, if the unit compartments and cooling conduits are defined by a single integral component, or indirectly thermally connected via separate conductive components. Therefore, the term "thermally connected" should be understood to refer to the possibility of transferring heat between the cooling conduits of one or more unit compartments and the unit housing. Conversely, for the context, if a component is insulated, it is not thermally connected to another component. For example, such an insulated component can be separated from another component by insulating material.

[0011] As used herein, the terms "stack" and "adjacent stack" refer to the relative positions of components above each other. Thus, in some examples, the stacked arrangement of cell housings may include adjacent stacked cell housings in direct contact with each other. In some preferred examples, the cell tower may include one or more other components or materials between adjacent stacked cell housings (i.e., between cell housings stacked one above the other). For example, the cell tower may include an adhesive or filler material between adjacent stacked cell housings. Advantageously, such an adhesive or filler material can compensate for manufacturing tolerances during cell tower assembly, such as dimensional tolerances that may affect the alignment of cell housings with each other. For example, a thixotropic adhesive may be particularly advantageous for filling gaps between adjacent cell housings during tower assembly. Additionally, in some examples, the adhesive or filler material may be thermally conductive and thus facilitate heat transfer between adjacent stacked cell housings.

[0012] In some examples, the battery tower may include gaskets disposed between the cooling pipe connector and the corresponding unit housing to which the cooling pipe connector is attached. In some examples, the gaskets, or each gasket, may include rubber. For example, the gaskets may include nitrile rubber. In some examples, the gaskets, or each gasket, may include silicone resin. In some examples, the gaskets, or each gasket, may include fiber-reinforced gaskets, i.e., the gaskets may include fibrous materials, for example, impregnated with rubber or silicone resin. In some preferred examples, the gaskets, or each gasket, may include elastomeric polymers, such as, for example, thermoplastic polyurethane (TPU). Therefore, the sealing gaskets, or each sealing gasket, may be overmolded thermoplastic polyurethane sealing gaskets. Sealing gaskets can improve the seal between the cooling pipe connector and the adjacent stacked unit housings to which it is attached. In particular, sealing gaskets can compensate for minor expansion or contraction of the unit housings and / or connectors due to temperature fluctuations during use, thereby ensuring a seal is maintained between the respective components. In some preferred examples, the battery tower may include multiple sealing gaskets, and each unit housing may be sealed to the cooling pipe connector with a corresponding individual gasket.

[0013] In some preferred examples, the cooling conduits of each unit housing may extend substantially horizontally within the respective unit housing. It is particularly advantageous to stack the unit housings, including the horizontally extending cooling conduits, vertically on top of each other. In examples where the cooling conduits comprise a cooling liquid (such as water), horizontally oriented cooling conduits can help minimize the risk of air (i.e., air bubbles) trapped in the cooling conduits during use, which may reduce the efficiency of heat transfer from one or more unit compartments during use. Additionally, configuring the battery tower with vertically stacked unit housings (each unit housing having multiple interconnected horizontally extending cooling conduits) during use can facilitate the expulsion of air from all cooling conduits in a single operation when all cooling conduits are first filled, as this arrangement avoids air trapping within the cooling conduits. Furthermore, in some examples, the unit housings and the one or more unit compartments defined by the unit housings may extend horizontally. In particular, in some examples, one or more unit compartments may extend longitudinally in the compartment direction along the unit compartment axis. Thus, the unit housings can be configured such that the unit compartment axes are substantially horizontal during use. Therefore, in use, cooling pipes that extend horizontally along the unit compartments within the unit housing can advantageously present a large surface area for transferring heat from the respective unit compartments to the cooling fluid in the cooling pipes.

[0014] In some preferred examples, in use, the cooling ducts, which extend "substantially horizontally," may be inclined at less than + / - 2 degrees relative to the horizontal plane (0 degrees), or more preferably at less than + / - 1 degree relative to the horizontal plane. Orienting the cooling ducts within this range and / or orienting the battery tower such that the cooling ducts extend within this range is particularly advantageous for minimizing the risk of air stagnation in the cooling ducts. It should be understood that the inclination of the cooling duct preferably refers to the angle defined between the horizontal line (i.e., 0 degrees) and the longitudinal axis of the cooling duct. Most preferably, the cooling ducts may not be inclined relative to the horizontal plane, i.e., in use, the cooling ducts may be inclined at 0 degrees relative to the horizontal plane.

[0015] In some examples, each cooling conduit may be substantially U-shaped. Therefore, each cooling conduit may include: a first portion configured to allow fluid to flow in a first direction; and a second portion configured to allow fluid to flow in a second direction substantially opposite to the first direction. Because U-shaped cooling conduits have a larger surface area for conducting heat from the respective unit compartment to the cooling fluid within the cooling conduit, U-shaped cooling conduits can be particularly advantageous for transferring heat away from one or more unit compartments during use and can contribute to a more uniform distribution of the cooling effect along the unit compartment.

[0016] Furthermore, as described in more detail later, in some examples, the battery tower may include more than two unit housings stacked one on top of the other. If each cooling duct is substantially U-shaped and each unit housing is oriented in the same manner, the cooling ducts of each unit housing in the stack may all begin and end on the same side of the battery tower. Therefore, the cooling ducts of adjacent stacked unit housings can be fluidly connected on the same side of the battery tower. This can facilitate the assembly and maintenance of the battery tower. Thus, each unit housing may include a connection end to which a cooling duct connector is attached, and each unit housing may be arranged such that its respective connection end is located on the same side of the battery tower.

[0017] In some examples, the first portion of the cooling conduit may be a lower portion, and the second portion may be an upper portion. The first and second portions of each cooling conduit may extend substantially horizontally within the unit housing. As previously described, in examples where the unit housing and one or more unit compartments defined by the unit housing extend horizontally, horizontally extending cooling conduits may be particularly advantageous for heat transfer and may help minimize the risk of air bubbles becoming trapped within the cooling conduits. Additionally, U-shaped cooling conduits can advantageously distribute the cooling effect achieved by the cooling fluid within the cooling conduits during use. For example, horizontally extending U-shaped cooling conduits may help reduce temperature variations and / or minimize temperature gradients along the horizontal length of the unit compartment or each unit compartment.

[0018] In some examples, the U-shaped cooling conduit of each unit housing may be at least partially defined by a channel extending through the entire length of the unit housing and an end cap blocking one end of the channel. It should be understood that in some such examples, the end cap preferably blocks the end of the channel opposite to the end of the cooling conduit that is fluidly connected to the cooling conduit by the cooling conduit connector; that is, the end cap may block the end of the channel opposite to the connecting end of the unit housing. Forming a unit housing with a U-shaped cooling conduit (which is at least partially defined by a channel extending through the entire length of the unit housing) can be advantageous for the simple and cost-effective manufacture of the unit housing.

[0019] In some examples, the U-shaped cooling conduit may be defined at least partially by two channels extending through the entire length of the unit housing. For example, a first portion may be defined by a first channel, and a second portion by a second channel. The first and second channels may be separated by a web that begins at the connecting end of the unit housing and extends toward the end cap. Preferably, this web does not extend to the end cap, or includes an opening near the end cap, thereby defining a gap that facilitates fluid communication between the first and second portions to form the U-shaped cooling conduit. In some examples, the unit housing may be manufactured by extrusion, and the web and the first and second channels extending through the unit housing may be formed simultaneously during the extrusion process. In such examples, the gap connecting the first and second portions of the cooling conduit may be formed by removing (e.g., machining) a portion of the web after the extrusion process.

[0020] In some examples, the end cap may include a sealing plug, such as a plastic or rubber plug, or a plastic plug including a rubber seal such as a nitrile rubber O-ring. In some other examples, the end cap may include a sealing plate attached to the front surface of the cell housing. For example, such a sealing plate may be bolted to the front surface of the cell housing. In examples including a sealing plate, the end cap may also include a sealing gasket disposed between the sealing plate and the cell housing. In some preferred examples, the battery tower may include similar or equivalent sealing gaskets on both sides of the cell housing (i.e., between the cell housing and each of the cooling duct connectors and sealing plates attached to the cell housing). This can be advantageous for reducing manufacturing complexity and cost. In some other preferred examples, the end cap may include a sealing plate attached to the front surface of the cell housing by means of an adhesive. In this way, the sealing plate can be bonded to the cell housing. Bonding the sealing plate to the cell housing can provide a dual benefit, as the adhesive both attaches the sealing plate to the cell housing and seals the sealing plate to the cell housing.

[0021] In some examples, the cooling pipe connector and end cap can be attached to the respective unit housing using a common bolt connection. For example, the unit housing can be sandwiched between the cooling pipe connector and the end cap. Therefore, the cooling pipe connector, unit housing, and end cap can be clamped together using the same connection device. In some preferred examples, each unit housing can be clamped between the cooling pipe connector and the corresponding end cap using two or more bolts that clamp the various components together.

[0022] In some examples, the battery tower may include a complex end plug arranged with each cell housing to define a corresponding end cap, at least a portion of a separating web between first and second portions of a cooling conduit, and a gap facilitating fluid communication between the first and second portions. For example, the cooling conduit may be partially defined by a single channel extending through the cell housing. In such an example, the complex end plug may be arranged to block the end of the channel, thereby forming an end cap, and the first and second portions of the cooling conduit may be defined at least partially by a separating web portion of the complex end plug. In such an example, the complex end plug may include a hole or gap through the separating web portion of the complex end plug, or between the web portion and the end cap portion, to facilitate fluid communication through the separating web, thereby forming a U-shaped cooling conduit.

[0023] In some examples, the cooling conduits of the cell housing can be U-shaped. The U-shaped cooling conduits can be defined by one or more channels formed in the cell housing. The U-shaped cooling conduits can be formed by blocking the ends of one or more channels. For example, the battery tower can include end caps arranged to block the ends of each channel, as previously described, thereby directing fluid flowing in a first section of the cooling conduit in the opposite direction to its flow in a second section of the cooling conduit.

[0024] The channels or each channel in the unit housing may extend longitudinally in the same direction as the unit compartments or each unit compartment of the corresponding unit housing. As previously described, in some examples, the unit compartments may extend substantially horizontally. Therefore, the channels or each channel forming the U-shaped cooling conduits may also extend substantially horizontally. In some preferred examples, the channels or each channel formed in the unit housing may extend at least the same length as the units or each unit located in the unit compartments or each unit compartment of the unit housing. Furthermore, in some examples, the channels or each channel in the unit housing may extend at least the same length as the unit compartments or each unit compartment. As previously described, in some preferred examples, the channels or each channel formed in the unit housing may extend through the entire length of the unit housing.

[0025] In some examples, a cooling pipe connector can fluidly connect a first portion of a cooling pipe in a cell housing to a second portion of a cooling pipe in an adjacent stack of cell housings. For example, a cooling pipe connector can fluidly connect the upper portion of a cooling pipe in a cell housing to the lower portion of a cooling pipe in an adjacent stack of cell housings. The upper portion of the cooling pipe may define an outlet, and the lower portion may define an inlet. Thus, the cooling pipe connector can fluidly connect the outlet of a cooling pipe in a cell housing to the inlet of a cooling pipe in an adjacent stack of cell housings. It should be understood that in some preferred examples, the cooling pipe connector can therefore fluidly connect adjacent cooling pipe portions of different adjacent stacks of cell housings. This configuration can advantageously simplify the manufacture of the battery tower.

[0026] In some examples, cooling conduits and cooling conduit connectors can together define a serpentine flow path through multiple adjacent stacked cell housings. Therefore, the cell tower can be configured such that the flow path defined by the cooling conduits and cooling conduit connectors of adjacent stacked cell housings is a series flow path, flowing sequentially through the cell housings, through the cooling conduit connectors, and subsequently through the adjacent stacked cell housings. This configuration can be advantageous for cooling performance in use and for ease of manufacture.

[0027] In some examples, the cooling conduits of the unit housing may extend along the respective unit compartment or substantially the entire length of each respective unit compartment. This configuration can help provide a large surface area for efficient heat transfer between the unit compartment and the fluid in the cooling conduits during use. It should be understood that, in some examples, the first and second portions of the cooling conduits of each unit housing may therefore extend along substantially the entire length of the respective unit compartment. Furthermore, in some examples, the cooling conduits of each unit housing may extend substantially across the entire height of the respective unit compartment. Again, in use, this configuration can be advantageous for heat transfer between the unit compartment and the cooling fluid in the cooling conduits.

[0028] In some examples, the unit housing may define multiple unit compartments. A unit housing defining multiple unit compartments can advantageously facilitate thermal management of multiple units in a compact, space-saving configuration. For example, in use, the same cooling conduits of the unit housing can be thermally coupled to multiple unit compartments, thereby facilitating efficient heat transfer between the conduits and the multiple unit compartments.

[0029] In some examples, multiple cell compartments of a cell housing can be defined in a configuration where they are stacked one on top of the other. In other words, each cell compartment of a given cell housing can be adjacent to (on top of or below) at least one other cell compartment of a corresponding cell housing. This stacking configuration can be space-efficient while still facilitating efficient heat transfer between the cell compartments and cooling conduits. Additionally, this configuration can simplify the manufacture and assembly of the cell tower.

[0030] In some examples, the battery tower may also comprise multiple units. Each unit may be located in a unit compartment within the unit housing. In some examples, the unit compartment may comprise multiple units, an arrangement that can be cost-effective and relatively quick to assemble. In some other examples, described in more detail later, each unit may be located individually in its own unit compartment.

[0031] In some examples, the respective units can be bonded to their respective unit compartments. Therefore, each unit compartment can include an adhesive for bonding the unit to the unit housing. Each unit compartment can include one or more inner surfaces. In some preferred examples, each unit can be bonded to each inner surface of the unit compartment in which the unit resides. For example, the battery tower can include an adhesive layer between each unit and its respective unit compartment. In some preferred examples, the adhesive layer between the unit and the respective inner surface of the unit compartment can be substantially continuous, i.e., uninterrupted and without gaps. More preferably, in some examples, the unit can be surrounded by a substantially continuous adhesive layer. The substantially continuous adhesive layer provides an advantageous thermal bridge between the unit and the unit housing for heat transfer during use.

[0032] In some examples, one or more other components may coexist with the unit in the respective unit compartment, as will be described in more detail later. In such examples, it is still preferable to provide a substantially continuous adhesive layer between the units and unit compartments for advantageous heat transfer. In some examples, one or more other components may therefore also be surrounded by the adhesive layer. Alternatively, the adhesive layer may be present between the unit and at least one other component within the unit compartment. Additionally or alternatively, the adhesive layer may be present between at least one other component and the unit compartment, particularly if no adhesive layer is present between the unit and at least one other component. This configuration helps ensure that the adhesive layer is preferably present on all sides between the units and unit compartments, which can facilitate the transfer of heat to and from the respective units.

[0033] In some preferred examples, the adhesive may have a thermal conductivity greater than 0.2 W / mK, more preferably greater than 0.3 W / mK, and even more preferably greater than 0.4 W / mK. Therefore, the adhesive is preferably thermally conductive to facilitate heat transfer from the unit or each unit to the respective unit compartments and cooling conduits. Furthermore, in some preferred examples, the adhesive may be electrically insulating. In some examples, the adhesive may be an epoxy-based or silicone-based adhesive. An example of a suitable adhesive may be Momentive® RTV627, which has a thermal conductivity of 0.31 W / mK.

[0034] In some examples, the adhesive may be referred to as a potting compound. The adhesive can advantageously accommodate manufacturing tolerances in both the cell and the cell housing, particularly in the cell compartments of the cell housing. For example, during the manufacture of the battery tower, when the cells or each cell is bonded to the respective cell compartments, the adhesive introduced into the cell compartments may have a viscosity of less than 25 Pa·s. Such an adhesive can advantageously spread thoroughly throughout the cell compartment, forming a continuous layer that provides a thermal bridge conducive to heat transfer. In some particularly preferred examples, the adhesive introduced into the respective cell compartments to bond the cells within the cell compartments may have a viscosity of less than 5 Pa·s to ensure that the adhesive flows throughout the cell compartment during assembly. This helps ensure that a substantially continuous thermal bridge is provided by the adhesive between the cell and the cell housing. As an example, particularly advantageous adhesives (such as Momentive® RTV627) may have a viscosity of less than 1.5 Pa·s. In some preferred embodiments, when the adhesive is used to bond the respective units in the unit compartment, the adhesive may be slightly flexible or compliant, i.e., not rigid, so that the adhesive layer can accommodate minor fluctuations in the volume of the unit in use, such as due to thermal expansion and contraction of the unit in use and venting during unit aging.

[0035] In some examples, in addition to the cells, a compliant material pad may be located within the respective cell compartments. The compliant material pad may be a compressible material configured to deform and mold in response to compressive forces. For example, the pad may be located between the cells and cell walls, i.e., between the cells and the inner surfaces of the cell compartments. Advantageously, the pad can thus provide a degree of flexibility within the cell compartments to allow for thermal expansion and contraction of the cells or each cell during use, particularly during charging and discharging. The pad may also provide flexibility to allow gases within the cells to cause the cells or each cell to expand, which may increase volume over the entire service life of the cells. The compliant material pad may comprise a foam pad. For example, in some examples, the pad may be formed from HT800 flame-retardant silicone foam. The combination of the compliant material pad and the adhesive layer disposed between the cells and cell compartments provides a hybrid solution that provides both compliance, i.e., flexibility (via the pad) to allow for variations in cell volume and compartment dimensional tolerances, and thermal conductivity (via the adhesive layer) to facilitate favorable temperature management of the cells.

[0036] As previously described, a substantially continuous adhesive layer between units and unit compartments can provide a substantially continuous thermal bridge between the unit and the unit housing for advantageous heat transfer. In examples where the unit compartments include compliant material (such as foam) pads, the adhesive in the unit compartments can preferably still be arranged to form a thermal bridge between the unit and the unit compartment walls of the unit housing. For example, in some examples, the compliant material pads may be surrounded by adhesive. Alternatively, an adhesive layer may be present between the unit and the compliant material pad. Additionally or alternatively, an adhesive layer may be present between the compliant material pad and the unit compartment, particularly if no adhesive layer is present between the unit and the pad. This configuration helps ensure that the adhesive layer is preferably present on all sides between the unit and the unit compartment, which increases the surface area of ​​the adhesive in contact with the unit and the unit compartment, thereby promoting particularly efficient heat transfer between the unit and the unit housing.

[0037] In some examples, the unit may be a bag unit comprising a flexible outer sheath and two conductive unit terminals. Therefore, the unit can be slightly compliant, which simplifies the arrangement of the unit within the respective unit compartment. Thus, the unit may not have a rigid container or external structure. Instead, in some examples, the unit may be supported within the respective unit compartment by an adhesive as described above.

[0038] In some examples, two unit terminals (i.e., a positive unit terminal and a negative unit terminal) may extend from opposite ends of the respective unit. In other examples, the positive and negative unit terminals of the respective unit may extend from the same end of the unit. The units (particularly the unit terminals) are preferably configured to facilitate electrical connection of each unit terminal to the unit terminal of another unit in the battery tower. Thus, during assembly, in some preferred examples, the unit terminals may protrude from the unit compartment housing the respective unit to facilitate simple electrical connection of the units. In some examples, the battery tower may include multiple units connected in series, i.e., the positive unit terminal of each unit may be connected to the negative unit terminal of a different unit. Alternatively, in some examples, the battery tower may include multiple units connected in parallel, i.e., the positive unit terminal of each unit may be connected to the positive unit terminal of a different unit. The unit compartments defined by the respective unit housings can facilitate the organization and alignment of units, thereby facilitating a faster and more efficient process of connecting the unit terminals during the manufacture of the battery tower.

[0039] In some examples, each unit can be located individually in its respective unit compartment. Therefore, in some examples, each unit compartment may comprise a single unit. Advantageously, in use, positioning each unit individually in its own unit compartment can be particularly effective for transferring heat away from the unit. For example, with this configuration, each unit can be close to multiple unit walls defining the respective unit compartment. Furthermore, this configuration can aid in the manufacture of the battery tower by facilitating a more repeatable and precise arrangement of each unit within the tower. This, in turn, simplifies the electrical connections of the terminals of each unit.

[0040] In some examples, each unit compartment may include a substantially rectangular cross-sectional profile defined at least partially by three unit compartment walls. Thus, a unit located within a respective unit compartment may be surrounded by the unit compartment on at least three sides. Furthermore, in some examples, each unit compartment may include a substantially rectangular cross-sectional profile defined by four unit compartment walls. Thus, a unit located within a respective unit compartment may be surrounded by the unit compartment on at least four sides. Surrounding the unit on three or more sides advantageously provides a considerable surface area to capture and transfer heat from the unit during use, and also protects the unit from damage during use.

[0041] In some preferred embodiments, the cross-sectional profile of the unit may be substantially the same shape as the unit compartment in which the unit resides. For example, in some preferred examples, each unit may include a substantially rectangular cross-sectional profile. Furthermore, in some examples, the aspect ratio of the unit may be substantially the same as the corresponding aspect ratio of the unit compartment in which the unit resides. It should be understood that, herein, the aspect ratio of a unit or unit compartment refers to the ratio of the width of the unit or unit compartment to its height. Substantially matching the shape and / or size of the units and unit compartments means that, during assembly, the units can be positioned close to the unit walls, thereby facilitating heat transfer and cooling of the units. Additionally, in examples where an adhesive layer is included between the unit and the corresponding unit compartment, substantially equal aspect ratios can result in an adhesive layer of substantially uniform thickness between the unit and any unit compartment wall.

[0042] In some examples, each cell compartment wall can be thermally coupled to the cooling conduits of the corresponding cell housing. This further improves heat transfer away from the cell during use, as heat transferred from the corresponding cell to the cell compartment wall can then be further conducted to the cooling conduits and the cooling fluid within them. Thus, this configuration facilitates very efficient cooling of the cells in the cell tower during use. The thermal coupling of the cell compartment walls and the cooling conduits (i.e., the fluid conduits) facilitates heat transfer between the conduits and the compartment walls, and therefore, in some examples, as previously described, also facilitates the transfer of heat from the conduits to the cell compartments.

[0043] In some examples, the cooling conduits of each unit housing may be at least partially defined by one or more conduit walls. Each unit compartment defined by a respective unit housing may be at least partially defined by a conduit wall. Thus, in some examples, each unit compartment may share a wall with the cooling conduits of the respective unit housing. In other words, in some examples, each unit housing may include a unit compartment wall that is also a conduit wall. In a preferred example, the conduit wall may be formed of a thermally conductive material. Thus, the conduit wall may be referred to as a thermally conductive wall. For example, the conduit wall or each conduit wall may include a thermally conductive material having a thermal conductivity of at least 150 W / mK, preferably at least 200 W / mK. In use, a unit housing including a conduit wall that also defines at least a portion of a unit compartment can provide a particularly direct route for conducting heat away from the unit and to the cooling fluid in the cooling conduits.

[0044] In some examples, each cell compartment defined by the respective cell housing may be at least partially defined by the same pipe wall. This configuration can be advantageous for encapsulating various features of the cell housing in a space-saving manner and also for facilitating the manufacture of the cell housing. Furthermore, this facilitates efficient heat transfer between adjacent cells in order to control thermal runaway in a single cell without triggering those nearby cells.

[0045] In some examples, each unit may extend longitudinally within a corresponding unit compartment. Therefore, the longitudinal axis of each unit may be substantially parallel to the axis of the corresponding unit compartment. The longitudinal axis of each unit may also be substantially parallel to the longitudinal axis of the cooling conduits of the corresponding unit housing. In some preferred examples, the cooling conduits thermally connected to the corresponding unit compartment may extend along the length of the unit compartment, which is at least equal to the length of the unit within the corresponding unit compartment. This can help provide effective cooling along the entire length of the corresponding unit during use, thereby avoiding temperature gradients and / or hot spots within the unit during use. It should be understood that the length of a unit as used herein may not include the unit terminals of the corresponding unit or the range of each unit terminal.

[0046] In some examples, a unit housing may comprise an assembly of individual components thermally coupled to each other. For example, a cooling conduit of a unit housing may be defined by a single component, and the unit compartments, or each unit compartment, of a corresponding unit housing may be defined by different components. Components may be attached to each other to form a unit housing, for example, permanently attached (e.g., by welding or bonding), or removably attached (e.g., via bolted or clamped connections). In particular, the different components in this example are thermally coupled to each other to ensure that heat can be transferred between one or more unit compartments and the cooling conduit. For example, both the cooling conduit and the unit compartment may be defined by thermally conductive components, such that attaching the components together thermally couples one or more unit compartments and the cooling conduit. Therefore, it should be understood that in some examples, references to "unit housing" herein may refer to a unit housing comprising an assembly of individual thermally coupled components.

[0047] In some other examples, the unit housing may include a single integral component defining each of the unit compartments and cooling conduits. Specifically, in examples where the cooling conduits are U-shaped, the U-shaped cooling conduits may be integrally formed with the unit housing. In particular, the first and second portions of the U-shaped cooling conduits may be integrally formed with the unit housing. Furthermore, means for providing fluid communication between the first and second portions of the U-shaped cooling conduits (i.e., fluid couplings such as the gaps in the webs described previously) may be integrally formed with the unit housing. Thus, in some examples, one or more unit compartments and cooling conduits may be integrally formed with the corresponding unit housing. This configuration can be advantageous for conducting heat from one or more unit compartments to the cooling conduits. Additionally, this configuration can facilitate simple and cost-effective manufacturing of the unit housing.

[0048] Therefore, in some examples, the entire unit housing can be formed from the same material; that is, the entire unit housing can be homogeneous. Aluminum can be a preferred material for the unit housing due to its thermal conductivity and relative ease of manufacture, particularly its suitability for extrusion, which allows for the efficient fabrication of long tubular sections. Thus, in some examples, the unit housing can be an extruded component. In some other examples, the unit housing can be a cast component. In some examples, the cast or extruded unit housing can be post-processed to form the upper and lower portions of cooling ducts, and / or to form gaps connecting the upper and lower portions, and / or to form through holes and threaded holes for receiving bolts during assembly of the battery tower.

[0049] In some examples, a battery tower may include three or more cell housings stacked one on top of the other. Cooling pipe connectors may be attached to each of the stacked cell housings to fluidly connect the cooling pipes of adjacent stacked cell housings. For example, the cooling pipe connector may define multiple individual conduits. Each conduit may fluidly connect the cooling pipes of two adjacent stacked cell housings. A single cooling pipe connector that fluidly connects the cooling pipes of three or more, preferably all, cell housings of a battery stack is particularly advantageous because by attaching a single cooling pipe connector to the respective cell housing, all individual cooling pipes can be fluidly connected in a single assembly operation.

[0050] In some preferred embodiments, the cooling pipe connector can be configured such that each conduit defined by the cooling pipe connector can be fluidly isolated from other conduits defined by the connector when it is not yet connected to a cell housing. Therefore, fluid communication between conduits can be facilitated only via the cooling pipes of the stacked cell housings. Thus, the cooling pipe connector can be configured to fluidly connect three or more, and preferably all, the cooling pipes of the cell housings in series. It is noteworthy that a single cooling pipe connector can therefore facilitate series fluid communication between all cooling pipes in the cell tower. In this way, the cooling pipe connector can be configured to form a series flow path through the cell housings, through the cooling pipe connectors, through adjacent stacked cell housings, and through each stacked cell housing in the cell tower. In some preferred embodiments, the cooling pipes and the multiple conduits defined by the cooling pipe connectors can together define a serpentine fluid flow path through the cell housings and the cooling pipe connectors.

[0051] Because a single cooling pipe connector connects multiple pairs of adjacent cooling pipes, this configuration provides a large exchange of fluid between the unit housing and the pipe connector while minimizing the number of individual components. This configuration also facilitates the use of relatively simple cast parts, such as for the cooling pipe connector, and promotes the use of gaskets for sealing between the housing and the cooling pipe connector. These gaskets can be clamped using simple fasteners. Therefore, this configuration results in a relatively simple assembly that promotes efficient heat transfer, is cost-effective, and is easy to assemble.

[0052] According to another aspect of the invention, a battery pack is provided, the battery pack comprising at least two battery towers according to any example described herein. The at least two battery towers are arranged side by side.

[0053] In some examples of the battery pack, the cooling conduits and cooling conduit connectors of the first battery tower may define a first flow path, and the cooling conduits and cooling conduit connectors of the adjacent second battery tower may define a second flow path. The battery pack may also include lower and upper transverse pipes connected to the cooling conduit connectors of each battery tower to fluidly connect the first and second flow paths. Therefore, the first and second flow paths may be parallel to each other. Thus, in use, cooling fluid can flow in parallel through the first and second flow paths, and the cooling fluid in the first and second flow paths can flow in series through the respective cell housings and cooling conduit connectors of the first and second battery towers. Allowing cooling fluid to flow through the parallel flow paths of the first and second battery towers can be advantageous for cooling performance, ensuring that the cells in both battery towers are cooled uniformly.

[0054] In some examples, the upper and / or lower lateral tubes may be integrally formed with the cooling pipe connectors of the first and / or second battery towers. Therefore, in some preferred examples, the cooling pipe connectors of the first and second battery towers may be defined by a single component. For example, the cooling pipe connectors of the first and second battery towers may be defined by a single cast component that defines a plurality of individual conduits configured to fluidly connect the cooling pipes of adjacent stacked cell housings of the first battery tower, and defines a plurality of individual conduits configured to fluidly connect the cooling pipes of adjacent stacked cell housings of the second battery tower. In such examples, the upper and lower lateral tubes may also be part of a single cast component, or in some examples may be defined by cast or machined channels, thereby facilitating fluid communication between the first and second flow paths as described above. Alternatively, in some examples, the upper and / or lower lateral tubes may be separate components connected, for example, via threaded connections to the respective cooling pipe connectors.

[0055] In some examples, the battery pack may also include a cooling fluid inlet upstream of a first cooling conduit defining a first flow path in a first battery tower. Additionally, the battery pack may include a cooling fluid outlet downstream of a final cooling conduit defining a second flow path in a second battery tower. In some examples, the cooling fluid inlet may be defined by a lower transverse conduit. Alternatively, in some preferred examples, the cooling fluid inlet may be defined by the lower end of a cooling conduit connector of the first battery tower. In some examples, the cooling fluid outlet may be defined by an upper transverse conduit. Alternatively, in some preferred examples, the cooling fluid outlet may be defined by the upper end of a cooling conduit connector of the second battery tower.

[0056] In some examples, the lower transverse pipe may be fluidly connected upstream of the respective first cooling pipe to the first and second flow paths, thereby defining the first and second flow paths in the respective first and second battery towers. Furthermore, in some examples, the upper transverse pipe may be fluidly connected downstream of the respective final cooling pipe to the first and second flow paths, thereby defining the first and second flow paths in the respective first and second battery towers. Thus, substantially the entire first flow path may be parallel to substantially the entire second flow path.

[0057] Therefore, in use, any cooling fluid entering the battery pack can be distributed between the first and second battery towers to cool the cells therein, and then the cooling fluids from the two flow paths are combined again at the outlet to facilitate efficient and space-saving handling of the cooling fluid downstream of the battery pack. For example, a heat exchanger can be arranged downstream of the cooling fluid outlet to remove heat from the cooling fluid before it is recirculated back to the cooling fluid inlet, such as using a circulation pump. In some preferred examples, the heat exchanger can be a cross-flow heat exchanger. Combining the fluids from the first and second flow paths into a single flow for delivery to such a heat exchanger and / or circulation pump simplifies the required piping.

[0058] In some examples, the battery pack may also include an expansion element to accommodate changes in the volume of the cooling fluid caused by fluctuations in the temperature of the cooling fluid during use. The expansion element may include a gas cavity contained in one of the fluid flow paths at a fixed location, such that the pressure of the gas cavity is directly related to the pressure of the cooling fluid in the first and second flow paths. For example, the gas cavity may be defined by a flexible diaphragm, or in some other examples, the gas cavity may be an air bubble intentionally trapped at a specific location, thus fixing it in place and preventing it from flowing through the battery pack with the cooling fluid during use. In some examples, the expansion element may be positioned above or below a cooling duct connector in one of the first or second battery towers. It is noteworthy that with this arrangement, in some preferred examples, other elements, such as fluid inlets or outlets, should not be connected downstream of the expansion element. In examples where the expansion element includes a gas cavity (such as a bubble) intentionally trapped at a specific location, other elements should not be connected above the expansion element, as this could otherwise remove the intentionally trapped gas cavity.

[0059] In some examples, the battery pack may include supplemental valves fluidly coupled to the first and second flow paths. For example, the supplemental valve may be connected to the upper or lower end of a cooling pipe connector in one of the first or second battery towers. In examples where the battery pack includes both an expansion element and a supplemental valve, they should preferably be connected to different cooling pipe connectors or at least different ends of the cooling pipe connectors. The supplemental valve facilitates the addition of cooling fluid to the first and / or second flow paths.

[0060] In some examples, the battery pack may also include a coolant pump located upstream of and fluidly coupled to the cooling fluid inlet. The coolant pump may be configured to propel cooling fluid into and through the flow paths of the first and second battery towers during use.

[0061] In another aspect of the invention, an alternative battery pack is provided. For ease of reference, the alternative battery pack will be referred to herein as a second battery pack. It should be understood that, without any contrary description detailing specific features of the second battery pack, all aspects of the previously described battery pack, the battery towers forming the battery pack, and components such as cells and cell housings are equally applicable to the second battery pack.

[0062] It is worth noting that in some examples, the second battery pack may include a connecting manifold instead of the separate cooling pipe connectors for the first and second battery towers described previously. The connecting manifold can provide essentially the same function as the cooling pipe connectors for the first and second battery towers described previously, namely, fluidly connecting the cooling pipes of adjacent stacked cell housings. However, the connecting manifold can provide a simplified arrangement for providing all fluid communication between the cooling pipes of the cell housings of the first and second battery towers in a single component. Furthermore, compared to the separate cooling pipe connectors described previously, the connecting manifold can optionally facilitate different fluid flows through the cooling pipes of the first and second battery towers, as will be described in more detail below.

[0063] In some preferred embodiments of the second battery pack, the cell housings of the respective battery towers can all be arranged in the same orientation, such that the connection ends of each cell housing are substantially aligned on the same side of the battery pack (e.g., the rear side of the battery pack). Furthermore, in some preferred embodiments, each cell housing of the respective battery tower can be arranged such that the cooling conduits of each respective cell housing are located on the same side of the battery tower, such as the left or right side of the respective tower. Therefore, the respective cooling conduits of the cell housings of the respective battery tower can be considered as stacked one on top of the other, or arranged in a stacked configuration.

[0064] Furthermore, the first and second battery towers (i.e., stacks of cell housings comprising cells) can be arranged side-by-side and oriented such that the cooling pipes of the corresponding cell housings of the first and second battery towers are arranged side-by-side. That is, in a preferred example, the cooling pipes of the cell housings of the first battery tower can be laterally adjacent to, i.e., adjacent to, the cooling pipes of the corresponding cell housings of the second battery tower. Therefore, the cooling pipes of all cell housings in the second battery pack can be arranged together in the central portion of the second battery pack. Advantageously, this simplifies the connection and sealing of the connecting manifolds.

[0065] It should be understood that "laterally adjacent" and "proximate" can include one or more other components or materials between adjacent cooling channels of corresponding adjacent cell housings. For example, the second battery pack can include an adhesive or filler material between adjacent cooling channels of corresponding adjacent cell housings. Advantageously, such an adhesive or filler material can compensate for manufacturing tolerances, such as dimensional tolerances of the cell housings, which may affect the alignment of the cell housings relative to each other, when assembling the second battery pack. For example, a thixotropic adhesive may be particularly advantageous for filling the gaps between adjacent cell housings during the assembly of the second battery pack. Additionally, in some examples, the adhesive or filler material can be thermally conductive. Thus, the adhesive or filler material can facilitate heat transfer between adjacent cell housings, particularly between adjacent cooling channels of the cell housings. In some preferred examples, the adhesive or filler material can be directly sandwiched between adjacent cooling channels without any other components in between.

[0066] In some examples, the connection manifold may be attached to and sealed to the connection end of each cell housing. For example, a second battery pack may include a seal or gasket between the connection manifold and the cell housing.

[0067] Alternatively, in some examples, the second battery pack may include one or more backplates disposed between the cell housing and the connecting manifold. For example, as described in more detail below, the backplate may be sealed (e.g., adhesively sealed) to the connection end of the cell housing. In particular, the backplate may include holes corresponding to cooling conduits of the cell housing attached to the backplate, especially holes corresponding to the inlet and outlet of each cooling conduit. The holes may also correspond to corresponding conduits of the connecting manifold. Thus, fluid communication between the connecting manifold and the corresponding cooling conduits of the cell housing can be provided via the backplate (i.e., via one or more holes in the backplate). Thus, the backplate can provide an interface between the connecting manifold and the cell housing. This configuration can advantageously simplify sealing the connecting manifold to the cell housing, and in particular simplify sealing the cooling conduits of the connecting manifold to the cell housing.

[0068] In some examples, the backplate can be attached to multiple cell housings. For example, a single backplate can be attached to and sealed to multiple adjacent stacked cell housings in a respective cell tower. Therefore, the backplate can also provide an interface between the connecting manifold and the multiple adjacent stacked cell housings. In some examples, a single backplate can be attached to and sealed to a corresponding pair of side-by-side adjacent (i.e., adjacent) cell housings in the first and second cell towers. Therefore, the backplate can also provide an interface between the connecting manifold and a corresponding pair of side-by-side adjacent (i.e., adjacent) cell housings. In some preferred examples, a single backplate can be attached to and sealed to multiple adjacent stacked cell housings in the first cell tower, and attached to and sealed to corresponding side-by-side adjacent (i.e., adjacent) cell housings in the second cell tower. For example, the backplate can be attached to and sealed to two adjacent stacked cell housings in the first cell tower and two corresponding side-by-side adjacent cell housings in the second cell tower. It should be understood that the backplate can therefore provide an interface between the connecting manifold, the corresponding cell housing attached to the backplate, and its corresponding cooling conduit. This configuration provides an advantageous and simple interface for fluidly connecting the connecting manifold to the corresponding cooling conduit. In some examples, sealing the connecting manifold to the backplate can be significantly simpler than sealing the connecting manifold to each individual unit housing and / or cooling pipe.

[0069] Therefore, in some examples, the second battery pack may include one or more sealing members disposed between the connecting manifold and the backplate or each backplate. For example, the sealing member or each sealing member may include a gasket as described above, such as an overmolded elastomeric polymer gasket comprising thermoplastic polyurethane. In some examples, the sealing member or each sealing member may include an overmolded cord seal. In some preferred examples, one or more sealing members may be integrally formed with one or more backplates. For example, the backplate or each backplate may include an integrally formed sealing member according to the examples described herein, wherein the integrally formed sealing member extends around a hole or each hole in the backplate. The integrally formed sealing member may further simplify the assembly of the second battery pack.

[0070] It is worth noting that in some examples, the unit compartments or each unit compartment of the unit housing may extend through the entire unit housing; that is, the unit compartments may have a tubular or pipe-like form. Therefore, the unit compartments or each unit compartment may be substantially open. This configuration may be a result of a manufacturing method (such as extrusion) used to form the unit housing. This configuration also facilitates the simple arrangement of the units or each unit compartment during manufacturing. A backplate may be attached to the unit housing to block the ends of the unit compartments or each unit compartment. Therefore, the backplate may help hold the units or each unit compartment during manufacturing. As described in more detail later, in some examples, the inner surface of the backplate may be spaced apart from the connecting ends of the unit housing to define a gap, through which fluid communication between the plurality of unit compartments defined by the unit housing can be facilitated during assembly.

[0071] It is worth noting that, in examples including a backplate, the backplate may preferably be sealed to the respective unit housing or the cooling conduits of each respective unit housing attached to the backplate, and particularly to the inlet and outlet of the cooling conduits. Specifically, this seal isolates the cooling conduits from the unit compartment fluid. Furthermore, this can help ensure that the cooling fluid flowing between the cooling conduits and the connecting manifold flows through the holes in the backplate in a simple flow path during use and does not leak into areas including electrical components such as units.

[0072] A connecting manifold may define a cooling fluid inlet for receiving a combined flow of cooling fluid. A connecting manifold may define a cooling fluid outlet for discharging the cooling fluid flow. In a preferred embodiment, the cooling fluid outlet may be configured to discharge the combined flow of cooling fluid. The connecting manifold may define a plurality of individual first conduits configured to fluidly connect the cooling conduits of adjacent stacked cell housings of a first battery tower. The connecting manifold may define a plurality of individual second conduits configured to fluidly connect the cooling conduits of adjacent stacked cell housings of a second battery tower.

[0073] In some examples, multiple first conduits and multiple second conduits can be separated from each other. Therefore, the second battery pack can include: a first flow path for guiding cooling fluid in series through the cooling pipes of the first battery tower and the first conduit of the connecting manifold; and a second flow path for guiding cooling fluid in series through the cooling pipes of the second battery tower and the second conduit of the connecting manifold. For example, after receiving a combined flow of cooling fluid at a cooling fluid inlet, the connecting manifold can be configured to split the combined flow into first and second flow paths, such that portions of the cooling fluid flow in series through the respective cooling pipes of the respective first and second battery towers. The connecting manifold can be configured to receive portions of the cooling fluid from the first and second flow paths after each portion of the cooling fluid has flowed in series through the cooling pipes of the respective battery tower. The connecting manifold can be configured to recombine portions of the cooling fluid flow to subsequently discharge the combined flow from a cooling fluid outlet downstream of the cooling pipes. Similar to the battery packs previously described, the first and second flow paths can therefore be corresponding series flows configured in parallel.

[0074] Alternatively, in some examples, the connecting manifold can be configured to facilitate mixing and temperature equilibrium between the fluid flowing through the first battery tower and the fluid flowing through the second battery tower. For example, in some preferred examples, each first conduit of the connecting manifold can be fluidly coupled to a corresponding second conduit of the connecting manifold. Thus, the connecting manifold can be configured to facilitate fluid communication between corresponding cooling pipes of corresponding cell housings in the first and second battery towers. In some examples, each pair of corresponding first and second conduits can be defined by a corresponding channel in the connecting manifold. Notably, each first conduit is preferably separate from each other first conduit, and each second conduit is preferably separate from each other second conduit. Thus, the connecting manifold can include multiple separate channels, each separate channel defining a first conduit and a corresponding second conduit. Thus, the connecting manifold can be configured to provide fluid communication between corresponding cooling pipes of cell housings in the first and second battery towers in parallel via the respective channels, while ensuring that fluid communication between cooling pipes of cell housings in the same battery tower is provided only in series or continuously.

[0075] Therefore, the connecting manifold can be configured such that each channel defined by the connecting manifold can be fluidly isolated from other channels defined by the connecting manifold when it has not yet been attached to and sealed to the unit housing, for example, via a backplate. Thus, fluid communication between channels can be facilitated solely through cooling conduits of the unit housing.

[0076] As an example, a connecting manifold can be configured to receive a combined flow of cooling fluid at a cooling fluid inlet. The connecting manifold can be configured to divide the combined flow into a first portion of cooling pipes flowing through a first cell housing of a first battery tower and a second portion of cooling pipes flowing through a corresponding cell housing of a second battery tower. The connecting manifold can be configured to receive the first and second portions of the cooling fluid flow via corresponding first and second conduits after the first and second portions of the cooling fluid flow have flowed through their respective cooling pipes. For example, the connecting manifold can be configured to recombine portions of the flow into a combined flow within channels defining the corresponding first and second conduits. Therefore, the connecting manifold can be configured to then divide the combined flow into another first portion of cooling pipes flowing through a cell housing of the first battery tower and another second portion of cooling pipes flowing through a corresponding cell housing of the second battery tower. The connecting manifold can be configured to fluidly connect all cooling pipes of the first and second battery towers in this manner to promote enhanced mixing and temperature equilibrium between the fluids flowing through the connecting pipes of the corresponding first and second battery towers.

[0077] Therefore, the connecting manifold can define multiple pairs of parallel fluid flow paths. Each pair of parallel fluid flow paths can thus include: a first flow path that directs a portion of the cooling fluid through cooling pipes in the unit housing of the first battery tower; and a second flow path that directs a portion of the cooling fluid through cooling pipes in the unit housing of the second battery tower. It should be understood that the connecting manifold can be configured to recombine portions of the cooling fluid into a combined flow at cooling fluid outlets downstream of all cooling pipes.

[0078] As previously mentioned, in some preferred embodiments, the cooling conduits of the cell housings in the second battery pack can be U-shaped cooling conduits. As previously mentioned, in examples where each cell housing is oriented in the same manner, each U-shaped cooling conduit of each cell housing in the corresponding battery tower begins and ends on the same side of the battery tower. In other words, each cooling conduit may include an inlet and an outlet, and in examples where the cooling conduit is U-shaped, the inlet and outlet of the corresponding cooling conduit may be located on the same side of the cell housing, such as at the connection end of the corresponding cell housing. With the cell housings oriented and arranged as previously described, the inlets and outlets of all cooling conduits in the second battery pack can be located in the central portion of the second battery pack. This arrangement facilitates assembly and sealing.

[0079] Therefore, in the example where the cooling conduit is a U-shaped cooling conduit, the corresponding conduit defined by the connecting manifold can be configured and arranged to fluidly connect the outlet of the cooling conduit of the corresponding unit housing to the inlet of the cooling conduit of the corresponding adjacent stacked unit housing. In other words, each first conduit of the connecting manifold can fluidly connect the outlet of the cooling conduit of the unit housing of the first battery tower to the inlet of the cooling conduit of the adjacent stacked unit housing of the first battery tower. Similarly, each second conduit of the connecting manifold can fluidly connect the outlet of the cooling conduit of the unit housing of the second battery tower to the inlet of the cooling conduit of the adjacent stacked unit housing of the second battery tower. It should be understood that the previous description of the corresponding first and second conduit pairs defined by the corresponding channels of the connecting manifold also applies to the example where the conduit (and therefore the corresponding channel) fluidly connects the outlet of the cooling conduit to the inlet of the cooling conduit of the adjacent stacked unit housing.

[0080] In another aspect of the invention, an electrically heated water system is provided, comprising a battery tower or battery pack as described in any example herein, including a second battery pack. The electrically heated water system may be an electric boiler suitable for supplying hot water to an outlet in a building and / or a water-based heating system. As previously described, in some examples, a heat exchanger (such as a crossflow heat exchanger) may be arranged downstream of the cooling fluid outlet of the battery pack or second battery pack. In such examples, heat from the cooling fluid flowing through the heat exchanger in use can be used to heat or preheat water in the electric boiler.

[0081] According to another aspect of the invention, a battery module is provided. The battery module includes a cell housing according to any example described herein. Thus, the cell housing defines at least one cell compartment and cooling conduits thermally coupled to the at least one cell compartment. The battery module also includes at least one cell according to any example described herein. The cell, or each cell, is located within a cell compartment defined by the cell housing.

[0082] In some preferred embodiments, the battery module may include multiple units. The unit housing may include multiple unit compartments. Each unit may be located individually in its respective unit compartment.

[0083] As previously described, in some examples, the cells or each cell may be bonded to a cell compartment. Therefore, the battery module may include an adhesive layer between the cells and the cell compartments. For example, the battery module may include an adhesive layer between at least three inner surfaces of the cells and the cell compartments. Thus, each cell may be substantially surrounded by an adhesive layer between the cell and the cell compartment wall on at least three sides, preferably at least four sides. In some examples, a compliant material pad may be located in the cell compartment or each cell compartment as previously described. The battery module may include an adhesive layer between the compliant material pad and the cell wall.

[0084] In some preferred examples, the battery module may also include a backsheet. It is noteworthy that, when a backsheet is included, the backsheet is preferably sealed to the cell housing. For example, the sealing may include adhesive bonding. Specifically, the backsheet may be sealed to the cell housing such that the cooling conduits of the cell housing are fluidly isolated from one or more cell compartments of the cell housing.

[0085] A battery module may include multiple cell housings attached to and sealed to a backsheet. Various examples of backsheets have already been described and will not be described in detail again for the sake of brevity. However, by reference, a battery module may include multiple adjacent stacked cell housings attached to and sealed to the same backsheet. Additionally or alternatively, a battery module may include multiple side-by-side adjacent (i.e., neighboring) cell housings attached to and sealed to the same backsheet. In examples where the battery module includes multiple cell housings, an adhesive or filler material may be disposed between the cell housings. This can facilitate heat conduction between the cell housings.

[0086] It should be understood that the second battery pack may include multiple battery modules. In some examples, the battery modules may be arranged in a stacked configuration. In some other examples, the battery modules may be arranged in a side-by-side adjacent configuration. In examples where the second battery pack includes multiple battery modules, adjacent stacked or side-by-side adjacent cell housings of different battery modules may be bonded together with an adhesive. Furthermore, it should be understood that in some examples, the second battery pack may include a connecting manifold attached to and sealed to the multiple battery modules to fluidly connect cooling channels of the cell housings of the battery modules, as previously described. The implementation of the battery modules facilitates a simple and efficient method for manufacturing the second battery pack, wherein each battery module can be manufactured individually before attaching and sealing the multiple battery modules to the connecting manifold.

[0087] According to another aspect of the invention, a method for manufacturing a battery module according to some examples described herein is provided. The method includes providing a cell housing according to any example described herein. The method further includes providing an adhesive in cell compartments or each cell compartment defined by the cell housing. The method also includes arranging at least one cell in the cell compartments or each cell compartment.

[0088] In some preferred embodiments, the method may include arranging the unit housing in an upright orientation before providing the adhesive into the unit compartment or each unit compartment. For example, the unit compartment or each unit compartment may extend longitudinally in the compartment direction along a respective compartment axis. The unit housing may be arranged in an upright orientation, wherein the compartment axis or each compartment axis extends substantially vertically. Thus, when the unit housing is arranged in an upright orientation, the opening of the unit compartment may face upward, with the unit compartment extending downward from the opening. In some such embodiments, the unit or each unit may be arranged in the unit compartment or each unit compartment by lowering the unit through the opening into the unit compartment.

[0089] In some examples, the method may include providing an adhesive in the unit compartment or each unit compartment before arranging the unit or each unit compartment in the unit compartment or each unit compartment. Therefore, the method may include arranging the unit or each unit compartment in the unit compartment or each unit compartment comprising the adhesive. In some examples, the unit may sink or be submerged in the adhesive within the unit compartment, such that an adhesive layer is formed between the unit and the unit compartment wall. As previously described, the unit housing may include multiple unit compartments. The battery module may include multiple units, each unit located in a separate unit compartment. Therefore, the method may include providing an adhesive in each unit compartment and subsequently arranging each unit in a separate unit compartment.

[0090] In some other examples, the method may include arranging the cells or each cell in the cell compartments or each cell compartment before introducing adhesive. For example, after arranging the cells in the cell compartments, the cell compartments may be filled with adhesive. This method can facilitate faster assembly of the battery module. As previously mentioned, the cell housing may include multiple cell compartments. The battery module may include multiple cells, each located in a separate cell compartment. Therefore, the method may include arranging each cell in its respective cell compartment and subsequently flooding each cell compartment with adhesive.

[0091] As previously described, the battery module may include a backplate. The backplate may include an inner surface. Therefore, the method may include sealing (e.g., adhesive sealing) the inner surface of the backplate to a connection end of the cell housing. Notably, the inner surface of the backplate may be sealed to the connection end of the cell housing such that cooling conduits of the cell housing are fluidly isolated from the cell compartments or each cell compartment.

[0092] The backplate may include at least one adhesive inlet. The method may include supplying (i.e., introducing) adhesive to the unit compartment or each unit compartment of the unit housing via the adhesive inlet in the associated backplate. In some examples, the backplate may include multiple adhesive inlets to facilitate faster supply of adhesive to the unit compartment or each unit compartment.

[0093] As previously described, the inner surface of the backplate can be sealed to the connection end of the unit housing, thereby fluidly isolating the cooling conduits of the unit housing from the unit compartments or each unit compartment. Therefore, the backplate may include one or more holes in a first portion to facilitate fluid communication through the cooling conduits of the backplate and the unit housing. The backplate may include one or more adhesive inlets in a second portion to facilitate fluid communication between the adhesive source and the unit compartments or each unit compartment.

[0094] In some examples, the backplate may include one or more protrusions or steps extending from the inner surface of the backplate. The protrusions or steps, or each protrusion or step, may be configured to engage the connecting ends of the unit housing such that, when the unit housing is attached, the inner surface of the backplate is spaced apart from the unit housing to form a gap between the inner surfaces of the unit housing. As previously mentioned, in some examples, the unit housing may define a plurality of unit compartments. Therefore, the backplate may be configured to facilitate fluid communication between the plurality of unit compartments via the gap defined between the unit housing and the inner surface of the backplate. In some examples, each unit compartment may be fluidly connected to at least one adhesive inlet via the gap defined between the inner surface of the unit housing and the backplate.

[0095] Therefore, the method may include providing adhesive in the unit compartment or each unit compartment via an adhesive inlet and a gap defined between the inner surfaces of the unit housing and the back panel. The adhesive may be provided in the unit compartment or each unit compartment in this manner, regardless of whether the adhesive is provided before or after the unit is arranged in the unit compartment. In either example, the adhesive provided to the unit compartment in this manner may advantageously diffuse around the unit compartment or each unit compartment, thereby forming a substantially continuous adhesive layer between at least one unit and the unit compartment wall.

[0096] As previously mentioned, in some examples, in addition to the unit, a compliant material pad may be located within the respective unit compartment. Therefore, the method may include arranging the compliant material pad in the unit compartment or each unit compartment. In some preferred examples, the method may include attaching the compliant material pad to the respective unit before the unit is arranged in the unit compartment. For example, the compliant material pad may include a self-adhesive foam pad that is attached (i.e., bonded) to the unit before the unit is arranged in the unit compartment.

[0097] In an additional example of a battery pack or second battery pack comprising multiple adjacent stacked cell housings, each cell housing may include a substantially unidirectional cooling conduit. In other words, the cooling conduit may be configured to guide and flow cooling fluid in a single direction during use. For example, each unidirectional cooling conduit may include a first end and an opposing second end. Each cooling conduit may be configured to allow cooling fluid to flow in a single direction, from the first end to the second end, or from the second end to the first end, depending on the orientation of the respective cell housing and the configuration of the battery tower.

[0098] In some examples, the unidirectional cooling conduit may be at least partially defined by a channel extending through the unit housing, as previously described. For example, the cooling conduit may be at least partially defined by a single channel extending through the unit housing. In some preferred examples, the channel may extend through the entire length of the unit housing. For example, the channel, and thus the unidirectional cooling conduit, may extend longitudinally from a connecting end of the unit housing to the front of the unit housing. Thus, a first end of the unidirectional cooling conduit may be defined by either the connecting end or the front of the respective unit housing, and a second end of the unidirectional cooling conduit may be defined by the other connecting end or the front of the respective unit housing. Furthermore, the unidirectional cooling conduit may be integrally formed with the unit housing, such that the unit housing may include a single integral component defining each of the unit compartments and the unidirectional cooling conduit.

[0099] In some preferred examples, each cell housing of a respective cell tower of a battery pack or second battery pack can be arranged such that the unidirectional cooling pipe of each respective cell housing is located on the same side of the cell tower, such as the left or right side of the respective tower. Therefore, the respective unidirectional cooling pipes of the cell housings of the respective cell towers can be considered as stacked one on top of the other, or arranged in a stacked configuration.

[0100] It is worth noting that, in examples including substantially unidirectional cooling conduits, the battery tower, battery pack, or second battery pack may include one or more front conduit connectors. It is also worth noting that the front conduit connectors, or each front conduit connector, may be arranged in place of the previously described end caps. Therefore, the front conduit connectors, or each front conduit connector, may be configured to provide fluid communication between the unidirectional cooling conduits of a pair of adjacent stacked cell housings. In other words, the front conduit connectors, or each front conduit connector, may define conduits that fluidly connect the unidirectional cooling conduits of a pair of adjacent stacked cell housings.

[0101] Furthermore, in examples including substantially unidirectional cooling conduits, the battery tower, battery pack, or second battery pack may include cooling conduit connectors or connecting manifolds configured to provide fluid communication between the unidirectional cooling conduits of a pair of adjacent stacked cell housings. For example, the cooling conduit connector or connecting manifold may define conduits that fluidly connect the unidirectional cooling conduits of a pair of adjacent stacked cell housings. Notably, the battery tower may be configured such that a first end of each unidirectional cooling conduit is connected to the cooling conduit connector or connecting manifold, and a second end of each unidirectional cooling conduit is connected to a front conduit connector. Notably, in a preferred example, the battery tower may be configured such that fluid communication is provided throughout the battery tower between the cooling conduits of a respective cell housing and the cooling conduits of adjacent stacked cell housings, alternately via the cooling conduit connector or connecting manifold, or via the front conduit connector or each front conduit connector.

[0102] Therefore, in some preferred embodiments, the cooling pipe connectors or connecting manifolds and the front pipe connectors or each front pipe connector, together with the unidirectional cooling pipes of adjacent stacked cell housings, can be configured to define a serpentine flow path through multiple adjacent stacked cell housings. For example, a corresponding cell tower can be configured such that the flow path defined by the unidirectional cooling pipes of adjacent stacked cell housings, the cooling pipe connectors or connecting manifolds, and the front pipe connectors or each front pipe connector is a series flow path. As an example, the flow path can be defined as guiding cooling fluid flow through the unidirectional cooling pipes of the cell housings, then through the conduits of the cooling pipe connectors or connecting manifolds, then through the unidirectional cooling pipes of adjacent stacked cell housings, and then through the conduits of the front pipe connectors and into the unidirectional cooling pipes of adjacent stacked cell housings, sequentially through all cell housings in the corresponding cell tower.

[0103] Therefore, in some examples, the battery tower can be configured such that, in use, cooling fluid flows through a unidirectional cooling pipe of each cell housing in a direction opposite to the direction of flow through the cooling pipes of adjacent stacked cell housings or each adjacent stacked cell housing. Thus, the battery tower can be configured such that, in use, cooling fluid flows alternately through the unidirectional cooling pipes of adjacent stacked cell housings from a first end to a second end of a corresponding cooling pipe, or from a second end to a first end of a corresponding cooling pipe. This configuration can be advantageous for cooling performance in use.

[0104] Therefore, cooling pipe connectors or connecting manifolds can be arranged on a first side of the respective battery tower, and the front pipe connectors or each front pipe connector can be arranged on an opposite second side of the battery tower. For example, the cooling pipe connectors or connecting manifolds can be connected to the connection ends of multiple unit housings, for example, via one or more backplates, and the front pipe connectors or each front pipe connector can be connected to the front surfaces of multiple unit housings. The front pipe connectors or each front pipe connector can be sealed to the front of the unit housing using any of the seals or gaskets described herein. Alternatively, in some other examples, the front pipe connectors or each front pipe connector can be adhesively bonded to the front surface of the respective unit housing, and thereby sealed to the front surface of the respective unit housing.

[0105] In some examples, a battery tower, battery pack, or second battery pack may include a single front coupling component defining multiple front pipe connectors. Such a front coupling component may define multiple individual conduits in a manner similar to that described in the previously referenced cooling pipe connectors and connecting conduits. In some examples of the second battery pack, the single front coupling component may define conduits that connect cooling pipes of adjacent (i.e., neighboring) pairs of adjacent stacked cell housings side-by-side. Such conduits may be fluidly coupled; for example, such pairs of corresponding conduits may be defined by corresponding channels in the front coupling component in a manner similar to that described in the previously referenced connecting manifolds and conduits.

[0106] It should be understood that all other aspects of the battery tower, battery pack, and second battery pack can be equally applied to and combined with this additional example of the battery pack or second battery pack. Attached Figure Description

[0107] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, wherein: Figure 1 A schematic perspective view of the unit housing defining multiple unit compartments and cooling pipes is shown; Figure 2 A schematic perspective view of a battery tower is shown, which includes multiple unit housings stacked one on top of the other; Figure 3 A schematic cross-sectional view of a portion of the battery tower is shown, which shows the cell compartments and cooling pipes of the cell housing in more detail; Figure 4 A schematic cross-sectional side view of a portion of the battery tower is shown, illustrating the flow path through the stacked cell housings; Figure 5a A schematic perspective front view of a battery pack including two battery towers arranged side by side is shown. Figure 5b A schematic three-dimensional rear view of the battery pack is shown; Figure 6 A schematic perspective view of the second battery pack is shown; Figure 7a A schematic cross-sectional view of the second battery pack is shown; Figure 7b A schematic cross-sectional view of the connection manifold for the second battery pack is shown; Figure 8 A schematic cross-sectional perspective view of the second battery pack is shown; Figure 9 A schematic diagram of the fluid flow through the second battery pack is shown; Figure 10a A schematic perspective view of the battery module is shown; and Figure 10b A schematic cross-sectional view of the battery module is shown. Detailed Implementation

[0108] Figure 1 This is a schematic perspective view of the unit housing 10. As will be described in more detail later with reference to the following figures, the unit housing 10 is configured to hold (i.e., fix) and cool one or more units 12 (in Figure 2 and Figure 3 (As shown in the diagram). Therefore, the unit housing 10 defines one or more unit compartments 14 for holding one or more units 12. Figure 1 As shown, in some examples, the unit housing 10 may define multiple unit compartments 14 for holding and cooling multiple units 12. To hold the units 12 in an organized and space-saving manner, the unit compartments 14 may be defined in a configuration where they are stacked one on top of the other, such as... Figure 1 As shown.

[0109] Each unit housing 10 also defines a cooling conduit 16. The cooling conduit 16 is thermally connected to a unit compartment 14 defined by the unit housing 10. Thus, heat from the unit compartment 14 can be conducted to the cooling conduit 16, and vice versa. It should be understood that the cooling conduit 16 is preferably configured to receive and guide the flow of cooling fluid during use. Examples of the flow paths defined by the cooling conduit 16 will be described in more detail later; however, as a brief overview, Figure 1 It provides an initial indication of how the unit housing 10 is configured to transfer heat between the unit 12 held in the unit compartment 14 and the cooling fluid in the cooling pipe 16 during use.

[0110] like Figure 2As shown in the schematic perspective view, multiple unit housings 10 can be stacked one on top of the other to form a battery tower 18. Although not shown in the figures, in some examples, the stacked unit housings 10 can be attached to a frame to maintain the position of the unit housings 10 relative to each other. Additionally or alternatively, in some examples, the stacked unit housings 10 can be bonded together with an adhesive. Brief Reference Figure 3 In some examples, the battery tower 18 may therefore include an adhesive layer 20 between adjacent stacked cell housings 10.

[0111] Refer again Figure 2 The cooling conduits 16 of adjacent stacked unit housings 10 are fluidly connected via cooling conduit connectors 22, which are attached to the adjacent stacked unit housings 10. For example... Figure 2 As shown in the example, the battery tower 18 may include three or more unit housings 10 stacked one on top of the other, and the cooling pipe connector 22 may be attached to each of the stacked unit housings 10 to fluidly connect their respective cooling pipes 16.

[0112] Still referencing Figure 2 The battery tower 18 preferably comprises a plurality of units 12. Each unit 12 preferably includes a positively conductive unit terminal 24a and a negatively conductive unit terminal 24b. The terminals 24 of each unit can be connected (not shown) to the terminals 24 of other units 12 to form a battery suitable for providing power to electrical equipment. Although not shown in the figures, the units 12 may be connected in series or in parallel depending on the requirements of a given application of the battery tower 18.

[0113] As previously described, the unit housing 10 is configured to hold (i.e., fix) the unit 12 while also facilitating heat transfer to manage the temperature of the unit 12, for example, by cooling the unit 12. Thus, each unit 12 is preferably located within a unit compartment 14 of the unit housing 10. For example, as... Figure 2 As shown, each unit 12 can be located individually in its respective unit compartment 14. This helps to keep the unit 12 in place and also promotes effective cooling of the unit 12, as will be referred to below. Figure 3 and Figure 4 A more detailed description.

[0114] First refer to Figure 3 It shows that by Figure 2The schematic cross-sectional view of the battery tower 18 shown by line AA indicates that each cell compartment 14 may be at least partially defined by a plurality of cell compartment walls 26. Each cell compartment wall 26 is preferably thermally connected to a cooling conduit 16 of the corresponding cell housing 10. In this way, the cell compartment walls 26 can facilitate the efficient and effective transfer of heat from the cell compartment 14 to the cooling conduit 16, thereby cooling the cell 12 in the corresponding cell compartment 14. In some examples, the cell housing 10 may comprise a single integral component defining each of the cell compartments 14 and the cooling conduit 16. This may be particularly effective for the uninterrupted conduction of heat from the cell compartments 14 to the cooling conduit 16 and vice versa.

[0115] exist Figure 3 In the example shown, each unit compartment 14 includes a generally rectangular cross-sectional profile and is at least partially defined by a plurality of unit compartment walls 26. In some preferred examples, the unit 12 located in the respective unit compartment 14 may be surrounded by the unit compartment 14 on at least three sides. Surrounding the unit 12 in this way within the unit compartment 14 provides a considerable surface area to receive heat from the unit 12 and conduct such heat away from the unit 12 during use. Figure 3 In the example shown, the unit 12 is surrounded by unit compartments 14 on four sides, thereby providing additional surface area through which heat is transferred away from the unit 12, and providing enclosed boundaries to help keep the unit 12 in the compartments 14 during manufacturing and use.

[0116] Still referencing Figure 3 In some preferred embodiments, unit compartment 14 may share wall 26i with cooling conduit 16 to provide a particularly efficient route for transferring unit heat to cooling fluid in cooling conduit 16 during use. For example, cooling conduit 16 may be at least partially defined by conduit wall 28. Figure 3 As shown, the pipe wall 28 can also define at least a portion of each unit compartment 14 of the corresponding unit housing 10, that is, at least a portion of the unit compartment wall 26i. Figure 3 In the example shown, each of the unit compartments 14 of each respective unit housing 10 is partially defined by the same conduit wall 28 of the respective unit housing 10. In a preferred example, the conduit wall 28 may be formed of a thermally conductive material having a thermal conductivity of at least 150 W / mK. Sharing walls 26i, 28 between the cooling conduit 16 and the unit compartment 14 minimizes the distance between the unit compartment 14 and the cooling conduit 16, thus being particularly advantageous for transferring heat away from the unit compartment 14 during use.

[0117] In some examples, each unit 12 can be bonded to its respective unit compartment 14. For example, epoxy or silicone-based adhesives 30 or potting compounds can be used to bond the unit 12 to the corresponding unit compartment 14, such as... Figure 3 As shown. Momentive® RTV627, with a thermal conductivity of 0.31 W / mk, can be an advantageous adhesive 30 for bonding unit 12 to the corresponding unit compartment 14. Adhesive 30 provides a thermal bridge to conduct heat directly from unit 12 to the corresponding unit compartment wall 26, thus potentially being particularly effective in transferring heat from unit 12 to compartment wall 26 during use.

[0118] In some particularly preferred examples, the adhesive 30 can be formed as a substantially continuous layer between the cell 12 and the corresponding cell wall 26 without gaps or air cavities. For example, during the manufacture of the battery tower 18, the adhesive 30 can be arranged in the cell compartment 14, and the battery cell 12 can then be introduced into the cell compartment 14 while the adhesive 30 is still substantially liquid, such that the cell 12 is at least partially immersed in the adhesive 30. This may cause the adhesive 30 to be squeezed into any free space within the cell compartment 14 between the cell 12 and the cell compartment wall 26, thereby forming a substantially continuous thermal bridge between the cell 12 and the corresponding cell compartment wall 26. Reference will be made later. Figure 10a and Figure 10b An example of a method for manufacturing a battery module, comprising a cell 12 bonded to a corresponding cell compartment 14 of a cell housing 10, is described in more detail.

[0119] Still referencing Figure 3 In some examples, unit 12 may be a bag unit including a flexible outer skin 32. This may be advantageous for assembling the battery tower 18, as unit 12 may be slightly compliant and therefore easier to fit into the corresponding unit compartment 14. The protective structure around each unit 12 may be provided by adhesive 30, which bonds unit 12 to the corresponding unit compartment 14, as previously described.

[0120] Figure 4 It shows the way Figure 2 The diagram shows a schematic cross-sectional view of the battery tower 18 of line BB. It should be understood that the configuration of the cooling pipe connector 22 is shown for clarity. Figure 4 The four uppermost unit housings 10 of the battery tower 18 are not shown in the diagram. Specifically, Figure 4The cross-sectional view in the figure illustrates an example of the flow path configuration defined by the cooling conduits 16 and cooling conduit connectors 22 of the battery tower 18. The cooling conduits 16 of the corresponding unit housing 10 preferably extend substantially along the entire length of the unit compartment 14 defined by the unit housing 10. In particular, the cooling conduits 16 preferably extend at least along the entire length of the unit 12 located in the unit compartment 14 of the corresponding unit housing 10.

[0121] like Figure 4 As shown, in some examples, the cooling conduit 16 of each unit housing 10 can be a substantially U-shaped cooling conduit 16. Thus, the cooling conduit 16 can each include: a first portion 16a (e.g., a lower portion) configured to allow fluid to flow in a first direction; and a second portion 16b (e.g., an upper portion) configured to allow fluid to flow in a second direction substantially opposite to the first direction. This configuration helps to distribute the cooling effect of the cooling fluid in the cooling conduit 16 more evenly along the length of the unit compartment 14 during use. In examples where the cooling conduit 16 includes upper and lower portions 16a, 16b, these portions can extend substantially horizontally within the unit housing 10. This can help reduce the risk of air or air bubbles becoming trapped in the cooling conduit 16 during use, which could potentially reduce cooling performance.

[0122] As previously described, the cooling pipe connector 22 fluidly connects the cooling pipes 16 of adjacent stacked unit housings 10. In an example where the cooling pipes 16 are substantially U-shaped and each unit housing 10 is oriented in the same manner, the cooling pipe connector 22 can fluidly connect a first portion 16a of the cooling pipe 16 of a unit housing 10 to a second portion 16b of the cooling pipe 16 of an adjacent stacked unit housing 10. For example, the first portion 16a of the cooling pipe 16 may define an inlet 33a of the cooling pipe 16, and the second portion 16b of the cooling pipe 16 may define an outlet 33b of the cooling pipe 16. Thus, the cooling pipe connector 22 can fluidly connect the outlet 33b of the cooling pipe 16 of a unit housing 10 to the inlet 33a of the cooling pipe 16 of an adjacent stacked unit housing 10. Therefore, the cooling pipes 16 and the cooling pipe connector 22 can together define a serpentine flow path through multiple adjacent stacked unit housings 10.

[0123] like Figure 4As shown, the same cooling pipe connector 22 can be configured to fluidly connect the cooling pipes 16 of three or more adjacent stacked unit housings 10. For example, the cooling pipe connector 22 can define a plurality of individual conduits 34, wherein each conduit 34 is configured to fluidly connect two adjacent stacked unit housings 10 cooling pipes 16. It is worth noting that in some such examples, the individual conduits 34 of the cooling pipe connector 22 may not be directly fluidly connected to each other. Thus, the conduits 34 can be fluidly isolated from each other, wherein fluid communication between the individual conduits 34 is facilitated only via the stacked unit housings 10 cooling pipes 16. Thus, in use, the cooling pipes 16 and the cooling pipe connector 22 can define a series flow path that guides cooling fluid in series through the unit housings 10 and the cooling pipe connector 22.

[0124] Still refer to Figure 4 But also refer to Figure 1 In some examples, the U-shaped cooling conduit 16 may be defined at least partially by a channel 36 extending through the entire length of the unit housing 10. As shown in the figures, in some examples, the unit housing 10 may include two channels 36 extending longitudinally through the unit housing 10. The channels 36 may be separated by a web 38, and a gap 40 may be provided in the web 38 to fluidly connect the two channels 36, thereby at least partially defining the U-shaped cooling conduit 16. Furthermore, an end cap 42 may block one end of each channel 36 to change the flow direction of the cooling fluid in the cooling conduit 16 during use. In some examples, such as Figure 4 In the example shown, end cap 42 may include a sealing plate attached to unit housing 10.

[0125] Figure 5a and Figure 5b A battery pack 44 is shown, comprising two previously described battery towers 18 arranged side-by-side. As previously described, cooling conduits 16 and cooling conduit connectors 22 of the respective battery towers 18 define flow paths through the battery towers 18. Thus, a first battery tower 18a includes a first flow path, and a second battery tower 18b includes a second flow path. The cooling conduits 16 of the different unit housings 10 in the respective battery towers 18 can be referenced relative to their relative positions along the respective flow paths. For example, each battery tower 18 includes a first cooling conduit that is the most upstream cooling conduit 16 defining the respective first or second flow path. Similarly, each battery tower 18 includes a last cooling conduit that is the most downstream cooling conduit 16 defining the respective first or second flow path. It should be understood that any other cooling conduits 16 of the respective battery towers 18 are located between the first and last cooling conduits, i.e., downstream of the first cooling conduit and upstream of the last cooling conduit.

[0126] In some examples, such as Figure 5b As shown, the battery pack 44 may include a lower transverse tube 48 and an upper transverse tube 50. These transverse tubes 48, 50 may be connected to the cooling pipe connector 22 of each battery tower 18 to fluidly connect the first and second flow paths. Thus, the first and second flow paths may be parallel flow paths, i.e., parallel to each other. In some examples, the lower transverse tube 48 may be fluidly connected upstream of a corresponding first cooling pipe in each battery tower 18 to the first and second flow paths. The upper transverse tube 50 may be fluidly connected downstream of a corresponding last cooling pipe in each battery tower 18 to the first and second flow paths. Therefore, substantially the entire portion of each flow path defined by the cooling pipes 16 of the unit housing 10 in the first and second battery towers 18a, 18b may be parallel to each other. This can help ensure a uniform distribution of cooling fluid between the first and second battery towers 18a, 18b during use, and also helps to substantially equalize the fluid pressure and flow rate in the first and second flow paths.

[0127] Still referencing Figure 5a and Figure 5b The battery pack 44 may include a cooling fluid inlet 52, which is fluidly coupled to a first flow path and upstream of a first cooling conduit. In examples including a lower transverse tube 48, in some preferred embodiments, the cooling fluid inlet 52 may be fluidly coupled to a first flow path upstream of the lower transverse tube 48. Thus, in such examples, the first and second flow paths may be substantially parallel downstream of the cooling fluid inlet 52.

[0128] The battery pack 44 may also include a cooling fluid outlet 54 fluidly connected to a second flow path and downstream of a final cooling conduit. In examples including the upper transverse tube 50, in some preferred embodiments, the cooling fluid outlet 54 may be fluidly connected to a second flow path downstream of the upper transverse tube 50. Thus, in some examples including upper and lower transverse tubes 48, 50 and cooling fluid inlet 52 and outlet 54, the first and second flow paths between the cooling fluid inlet 52 and the cooling fluid outlet 54 may be parallel to each other.

[0129] like Figure 5a and Figure 5bAs shown, in some examples, inlet 52 and outlet 54 may be defined by the ends of corresponding cooling pipe connectors 22. For example, inlet 52 may be defined by the lower end 56a of the cooling pipe connector 22a of the first battery tower 18a (i.e., the lower end 56a of the first cooling pipe connector 22a). Outlet 54 may be defined by the upper end 58b of the cooling pipe connector 22b of the second battery tower 18 (i.e., the upper end 58b of the second cooling pipe connector 22b). Preferably, the inlets and outlets 52, 54 may be positioned substantially opposite to the first and second flow paths. Therefore, the length of each flow path between the inlets and outlets 52, 54 is preferably substantially the same, and this may also help to maintain substantially the same fluid pressure in each flow path.

[0130] Although Figure 5a and Figure 5b An inlet 52 is shown at the lower end 56a of the first cooling pipe connector 22a and an outlet 54 is shown at the upper end 58b of the second cooling pipe connector 22b. However, it should be understood that the positions of the inlet and outlet 52, 54 can be interchanged. In fact, in some examples, the inlet 52 may be located at the upper end 58a of the first cooling pipe connector 22a and the outlet 54 may be located at the lower end 56b of the second cooling pipe connector 22b, and vice versa.

[0131] In some examples, battery pack 44 may include one or more additional components, such as supplemental valves (not shown) for introducing additional cooling fluid into the first and second flow paths, and / or expansion elements (not shown) for compensating for changes in cooling fluid pressure during use. In some examples, such additional components may be connected to the ends 56, 58 of the first or second cooling pipe connectors 22a, 22b, excluding the inlet 52 or outlet 54. For each of these components, the location may be substantially interchangeable, provided they are fluidly coupled to the flow path to perform the desired function. Additionally, although not shown in the figures, battery pack 44 may include a coolant pump, i.e., a circulation pump, configured to push cooling fluid into and through each flow path in battery pack 44. In some preferred examples, such a coolant pump may be located upstream of and fluidly coupled to the cooling fluid inlet 52.

[0132] Now for reference Figures 6 to 9This illustrates an alternative battery pack 60. For ease of reference, the alternative battery pack 60 may be referred to herein as a second battery pack 60. The second battery pack 60 is similar to the previously described battery pack 44 and includes many of the same features as battery pack 44. Therefore, it should be understood that equivalent features will not be described in detail again. Furthermore, in all examples described herein, equivalent features retain the same reference numerals. To avoid ambiguity, any features previously described with reference to battery pack 44 are equally applicable to the second battery pack 60.

[0133] The second battery pack 60 includes a plurality of cell housings 10 according to the foregoing example. Each cell housing 10 includes at least one cell compartment 14, and at least one cell 12 is located in each cell compartment 14. Figures 6 to 9 In the example shown, each unit housing 10 defines three separate unit compartments 14, and each unit 12 is located individually in its own unit compartment 14. Furthermore, as previously mentioned, the cooling conduits 16 of the unit housing 10 can be substantially U-shaped, such that the inlet 33a and outlet 33b of each cooling conduit 16 can be located at the connecting ends of the respective unit housing 10. In some preferred embodiments, the unit housing 10 can be entirely arranged and oriented such that the cooling conduits 16, particularly the inlets and outlets 33a, 33b of the cooling conduits 16, are located in the substantially central portion of the second battery tower 60.

[0134] Multiple cell housings 10 are arranged in a stacked configuration, and the second battery pack 60 includes multiple cell housings 10 arranged side by side. Therefore, the second battery pack 60 can be considered to include multiple battery towers 118 arranged side by side, similar to the battery towers 18 previously described with reference to battery pack 44. However, as previously stated, the cell housings 10 of the battery towers 118 of the second battery pack 60 can be oriented such that the corresponding cooling conduits 16 are centrally arranged, and it is noteworthy that the battery towers 118 of the second battery pack 60 do not include the same cooling conduit connectors 22 as previously described.

[0135] Instead, the second battery pack 60 includes a connecting manifold 62. The connecting manifold 62 is used to fluidly connect the cooling pipes 16 of the cell housings 10 in each battery tower 118 in a manner substantially similar to that of the cooling pipe connector 22. However, the connecting manifold 62 provides fluid communication between the cooling pipes 16 of the first battery tower 118a and between the cooling pipes 16 of the second battery tower 118b in a single component. Therefore, specific reference is made to... Figure 7b and Figure 8 Cross-sectional view and Figure 9As shown in the schematic diagram, the connecting manifold 62 defines a plurality of first conduits 34a, which are configured to fluidly connect to the cooling conduits 16 of the unit housing 10 of the first battery tower 118a. The connecting manifold 62 also defines a plurality of second conduits 34b, which are configured to fluidly connect to the cooling conduits 16 of the unit housing 10 of the second battery tower 118b. Figure 7b and Figure 8 As shown, the respective first conduits 34a are preferably isolated from each other in the connecting manifold 62 and are fluidly connected only via the cooling pipes 16 of the respective unit housing 10. The same applies to the plurality of second conduits 34b.

[0136] It is worth noting that the paired first and second conduits 34a and 34b can be defined by corresponding channels 64 in the connecting manifold 62. For example, a corresponding channel 64 in the connecting manifold 62 can define a first conduit 34a that fluidly connects to the cooling pipes 16 of two adjacent stacked cell housings 10 of the first battery tower 118a, and the same channel 64 can define a corresponding second conduit 34b that fluidly connects to the cooling pipes 16 of two corresponding adjacent cell housings 10 of the second battery tower 118b. (See also: Special Reference) Figure 9 In the view shown, the connecting manifold 62 can therefore be configured to receive a combined flow of cooling fluid at the cooling fluid inlet 52, to split the flow into two portions, each portion of the cooling fluid flowing through a cooling conduit 16 of the unit housing 10 of one of the first or second battery towers 118a, 118b, and then recombine these portions of the cooling fluid in a channel 64. The channel 64 can define corresponding pairs of first and second conduits 34a, 34b, such that the combined flow of cooling fluid can then be split into two portions again, each flowing through a corresponding cooling conduit 16 of the unit housing 10 of one of the first or second battery towers 118a, 118b, and then these portions of the cooling fluid are again recombine in the channel 64 of the connecting manifold 62.

[0137] The cooling pipes 16 of all cell housings 10 in the second battery pack 60 can be fluidly connected in this manner. Therefore, the cooling pipes 16 of the corresponding battery towers 118a and 118b can be fluidly connected in series, and the cooling pipes 16 of corresponding pairs of adjacent cell housings 10 can be fluidly connected in parallel. This configuration promotes mixing between the cooling pipes 16 of the first and second battery towers 118a and 118b during use, thereby improving temperature balance.

[0138] The connecting manifold 62 may also define a cooling fluid outlet 54 downstream of all cooling pipes 16, such that a combined flow of cooling fluid can be discharged from the connecting manifold 62 after flowing through the respective cooling pipes 16 of each battery tower 118a, 118b. As described in more detail later, the cooling fluid outlet 54 may be fluidly coupled to a heat exchanger (not shown) to recirculate heat from the cooling fluid for functional purposes.

[0139] Now for reference Figure 10a Schematic 3D diagram and Figure 10b In the cross-sectional view shown, in some examples, the second battery pack 60 may include a backplate 66. For example, the backplate 66 may be attached to the cell housing 10, and the connecting manifold 62 may be fluidly connected to a corresponding cooling conduit 16 via a corresponding hole 68 in the backplate 66. In some examples, such as Figure 10a and Figure 10b As shown, a single backplate 66 can be attached to multiple stacked and / or adjacent unit housings 10. Including the backplate 66 simplifies the connection and sealing of the connection manifold 62 to the corresponding unit housing 10, and in particular to the connection and sealing of the cooling conduits 16 of the unit housing 10.

[0140] Advantageously, in some examples, the configuration of the second battery pack 60 can facilitate modular manufacturing. For example, the second battery pack 60 may include multiple battery modules 70, each of which can be manufactured individually, i.e., offline, and then assembled together and fluidly coupled with a connection manifold 62 to form the second battery pack 60. Therefore, reference will now be primarily made to... Figure 10b The method of manufacturing the battery module 70 is described, but reference is still made to the previously described figures.

[0141] For reference, the battery module 70 may include at least one cell housing 10 defining at least one cell compartment 14, and at least one cell 12 may be adhesively bonded to the at least one cell compartment 14. (See Figures 10 and...) Figure 10b In the example shown, the battery module 70 may include a plurality of unit housings 10, each unit housing defining a plurality of individual unit compartments 14. Each unit compartment 14 may accommodate a single unit 12 as described above.

[0142] The method includes providing a unit housing 10 and providing an adhesive 30 in unit compartments 14 or each unit compartment 14 defined by the unit housing 10. For example, the adhesive 30 may be a potting compound, such as Momentive® RTV627, which has low viscosity and high thermal conductivity. The method also includes arranging units 12 in the respective unit compartments 14.

[0143] In some examples, after the adhesive 30 is provided in the unit compartment 14, the unit 12 can be arranged in the unit compartment 14. This allows the unit 12 to be lowered into and substantially immersed in the adhesive 30 in the unit compartment 14, thereby forming a layer of adhesive 30 between the unit 12 and the unit compartment wall 26. It should be noted that, for clarity, Figure 10b Adhesive 30 is not shown in the diagram, i.e. Figure 10b The module is shown before adhesive 30 is provided in unit compartment 14.

[0144] In some preferred examples, the unit 12 may be arranged in the unit compartment 14 before the adhesive 30 is introduced into the unit compartment 14. For example, refer to Figure 10b In some examples, the unit housing 10 may be arranged in an upright configuration, and the unit 12 may be located in a corresponding unit compartment 14. The unit compartment 14 may then be filled with adhesive 30 to surround the unit 12, thereby forming a layer of adhesive 30 that bonds the unit 12 to the unit compartment wall 26.

[0145] It is worth noting that in some preferred embodiments, the battery module 70 may include a backplate 66 as described above. Figure 10a and Figure 10b As shown, the battery module 70 may include a plurality of unit housings 10 attached to a backplate 66. While the benefits of the backplate 66 in providing a simplified sealing mechanism have been previously described, in some examples, the backplate 66 may also be advantageous for manufacturing the battery module 70.

[0146] For example, when adhesive 30 is supplied to unit compartment 14 and units 12 or each unit 12 are arranged in unit compartment 14, the backplate 66 attached to the plurality of unit housings 10 can provide stability. Additionally, in some examples, the backplate 66 can be configured to supply adhesive 30 to the unit compartment 14. For example, the backplate 66 may include one or more adhesive inlets 72 through which adhesive 30 can be supplied to the unit compartment 14. When the unit housings 10 or each unit housing 10 are arranged in an upright orientation, i.e., such that the unit compartment 14 extends substantially vertically from the backplate 66, supplying adhesive 30 to the unit compartment 14 via the backplate 66 can result in bottom-up filling of the unit compartment 14. Flooding the unit compartment 14 with adhesive 30 (i.e., potting compound) in this manner can facilitate a simplified manufacturing process and ensure accurate delivery of adhesive 30 to the unit compartment 14.

[0147] It is worth noting that in some examples, the backplate 66 may include one or more protrusions, steps, or shoulders 74 configured to engage the unit housing 10. Such protrusions can maintain a gap 76 between the inner surface 78 of the backplate 66 and the unit housing 10. Advantageously, this configuration can facilitate fluid communication between the unit compartments 14. This, in turn, means that adhesive 30 can be supplied from a single adhesive inlet 72 or from a reduced number of adhesive inlets 72 via the gap 76, which is in fluid communication with each unit compartment 14. Advantageously, this can facilitate the supply of adhesive 30 to each unit compartment 14 substantially simultaneously. Therefore, the method may include supplying adhesive 30 to each unit compartment 14 via the adhesive inlet 72 and via the gap 76 between the backplate 66 and the unit housing 10.

[0148] Referring more generally to all the accompanying drawings, it should be understood that the examples shown are provided by way of example only, and that many different combinations of configurations and features still fall within the scope of the invention as defined by the appended claims.

[0149] For example, as previously stated, although the description provided herein primarily relates to cooling unit 12 in use, the battery towers 18, 118 and their unit housings 10 are configured to facilitate heating and cooling of unit 12 in use. Therefore, the battery towers 18, 118 and the unit housings 10 are configured to help maintain the unit temperature within a desired range for optimal performance and / or lifespan, for example, by facilitating an increase in the temperature of unit 12 or cooling of unit 12 based on the unit temperature.

[0150] Furthermore, while each example of the unit housing 10 shown in the accompanying drawings includes multiple unit compartments 14, it should be understood that in some examples, the unit housing 10 may have only one unit compartment 14, and such a unit housing 10 can still achieve the benefit of simultaneously holding and cooling one or more units 12 located in the unit compartment 14. Similarly, while each illustrated example of the unit compartment 14 described herein includes four unit compartment walls 26, it should be understood that in some examples, three compartment walls 26 may be sufficient to help hold the unit 12 and conduct heat away from the unit 12.

[0151] Furthermore, the examples shown in the accompanying drawings all include unit compartments 14 partially defined by the same pipe wall 28 in the respective unit housing 10, i.e., the same pipe wall 28 is shared with each unit compartment 14 of a given unit housing 10. However, it should be understood that in some examples, the unit housing 10 may include unit compartments 14 that do not share the same pipe wall 28. For example, a cooling conduit 16 may be defined by two or more pipe walls 28, including a first pipe wall and a second pipe wall 28. In some examples, the unit housing 10 may include one or more unit compartments 14 partially defined by a first pipe wall and one or more unit compartments 14 partially defined by a second pipe wall. For example, the cooling conduit 16 may be a central cooling conduit 16 configured to allow cooling fluid to flow between different unit compartments 14 of the same unit housing 10.

[0152] The battery towers 18, 118, or battery packs 44, 60 described herein can be adapted to many different applications. For example, the battery towers 18, 118, or battery packs 44, 60 can be used as the main power source for drive components in vehicles such as boats or trains, or as auxiliary power sources for such vehicles. However, in preferred examples, the battery towers 18, 118, or battery packs 44, 60 described herein can be implemented in static applications. For example, the battery towers 18, 118, or battery packs 44, 60 can be used as a power source for domestic or commercial electrical systems, or as a backup power source to replace fossil fuel generators, to name just a few possible examples.

[0153] In some particularly advantageous examples, battery towers 18, 118, or battery packs 44, 60 can form part of an electrically heated water system (not shown). For example, such a water heating system may include an electric heating element that is at least partially powered by electricity from the cells 12 in battery towers 18, 118, or battery packs 44, 60. Some examples of battery towers 18, 118, or battery packs 44, 60 may include a heat exchanger for removing heat from cooling fluid flowing through cooling pipes 16 of the respective cell housings 10 during use. For example, the cooling fluid outlet of battery packs 44, 60 may be fluidly coupled to the heat exchanger, allowing the cooling fluid to flow to the heat exchanger after passing through the cooling pipes 16 of the cell housings 10 of battery packs 44, 60. Such a heat exchanger may be configured to preheat water in the electrically heated water system, such that the water can first be heated by heat removed from the cells 12 in battery towers 18, 118 before being heated by the heating element. This can provide a more efficient water heating system, as heating water to the desired temperature using a main heating element may require less electricity. In some examples, the heat exchanger (not shown) may be a crossflow heat exchanger.

[0154] It should be understood that any feature associated with the various examples above can be readily combined with any other feature described with reference to the different examples without departing from the scope of the invention as defined in the appended claims. Furthermore, it should be understood that the above description and drawings are provided by way of example only. Therefore, many alternatives to the specific examples provided above are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. A battery tower (18), comprising: Multiple unit housings (10) are stacked on top of each other, each unit housing defining at least one unit compartment (14) and a cooling pipe (16) thermally connected to the at least one unit compartment. as well as Cooling pipe connector (22) is attached to two adjacent stacked unit housings to fluidly connect the cooling pipes of the two adjacent stacked unit housings.

2. The battery tower (18) according to claim 1, wherein, Each cooling conduit (16) is a substantially U-shaped cooling conduit, the cooling conduit comprising: a first portion (16a) configured to allow fluid to flow in a first direction; and a second portion (16b) configured to allow fluid to flow in a second direction substantially opposite to the first direction.

3. The battery tower (18) according to claim 2, wherein, The first portion (16a) is the lower portion and the second portion (16b) is the upper portion, wherein the first portion and the second portion of each cooling pipe (16) extend substantially horizontally within the unit housing (10).

4. The battery tower (18) according to claim 3, wherein, The U-shaped cooling conduit (16) of each unit housing (10) is defined at least in part by a channel (36) extending through the entire length of the unit housing and an end cap (42) blocking one end of the channel.

5. The battery tower (18) according to any one of claims 2 to 4, wherein, The cooling pipe connector (22) fluidly connects the first portion (16a) of the cooling pipe of the unit housing (10) to the second portion (16b) of the cooling pipe of the adjacent stacked unit housing.

6. The battery tower (18) according to claim 5, wherein, The cooling conduit (16) and the cooling conduit connector (22) together define a serpentine flow path through multiple adjacent stacked unit housings (10).

7. The battery tower (18) according to any one of the preceding claims, wherein, The cooling pipes (16) of the unit housing (10) extend substantially along the entire length of the corresponding unit compartment (14) of the unit housing or each unit compartment.

8. The battery tower (18) according to any one of the preceding claims, wherein, The unit housing (10) defines a plurality of unit compartments (14).

9. The battery tower (18) according to claim 8, wherein, The plurality of unit compartments (14) of the unit housing (10) are defined in a configuration in which they are stacked one on top of the other.

10. The battery tower (18) according to any one of the preceding claims further includes a plurality of units (12), wherein, Each unit is located in a unit compartment (14) of the unit housing (10).

11. The battery tower (18) according to claim 10, wherein, The corresponding unit (12) is bonded to the unit compartment (14) in which it is located.

12. The battery tower (18) according to claim 10 or claim 11, wherein, The unit (12) is a bag unit comprising a flexible outer skin (32) and two conductive unit terminals (24).

13. The battery tower (18) according to any one of claims 10 to 12, wherein, Each unit (12) is located separately in its corresponding unit compartment (14).

14. The battery tower (18) according to claim 13, wherein, Each unit compartment (14) includes a substantially rectangular cross-sectional profile defined at least partially by three unit compartment walls (26), wherein the unit (12) located in the respective unit compartment is surrounded by the unit compartment on at least three sides.

15. The battery tower (18) according to claim 14, wherein, Each unit compartment wall (26) is thermally connected to the cooling pipe (16) of the corresponding unit housing (10).

16. The battery tower (18) according to any one of the preceding claims, wherein, The cooling conduit (16) of each unit housing (10) is at least partially defined by one or more conduit walls (28), and each unit compartment (14) defined by the respective unit housing is at least partially defined by a conduit wall.

17. The battery tower (18) according to claim 16, wherein, Each unit compartment (14) defined by the corresponding unit housing (10) is at least partially defined by the same pipe wall (28).

18. The battery tower (18) according to claim 16 or claim 17, wherein, The pipe wall (28) or each pipe wall comprises a thermally conductive material having a thermal conductivity of at least 150 W / (mK).

19. The battery tower (18) according to any one of the preceding claims, wherein, The unit housing (10) includes a single integral component defining each of the unit compartments (14) and the cooling pipes (16).

20. The battery tower (18) according to any one of the preceding claims, wherein, The battery tower includes three or more unit housings (10) stacked one on top of the other, wherein the cooling pipe connector (22) is attached to each of the stacked unit housings to fluidly connect the cooling pipes (16) of the adjacent stacked unit housings.

21. A battery pack (44) comprising at least two battery towers (18) according to any one of the preceding claims, wherein, The at least two battery towers are arranged side by side.

22. The battery pack (44) according to claim 21, wherein, The cooling pipe (16) and cooling pipe connector (22) of the first battery tower (18a) define a first flow path, and the cooling pipe and cooling pipe connector of the adjacent second battery tower (18b) define a second flow path. Furthermore, the battery pack (44) also includes a lower horizontal pipe (48) and an upper horizontal pipe (50) connected to the cooling pipe connector of each battery tower to fluidly connect the first flow path and the second flow path.

23. The battery pack (44) according to claim 22, further comprising: Cooling fluid inlet (52), which is upstream of a first cooling pipe that defines the first flow path in the first battery tower (18a); and cooling fluid outlet (54), which is downstream of a final cooling pipe that defines the second flow path in the second battery tower (18b).

24. The battery pack (44) according to claim 23, wherein, The lower transverse pipe (48) is fluidly connected upstream of the corresponding first cooling pipe to the first flow path and the second flow path, the corresponding first cooling pipe defining the first flow path and the second flow path in the corresponding first battery tower and second battery tower (18a, 18b). Furthermore, the upper transverse pipe (50) is fluidly connected downstream of the corresponding final cooling pipe to the first flow path and the second flow path, the final cooling pipe defining the first flow path and the second flow path in the corresponding first and second battery towers.

25. The battery pack (44) according to claim 23 or claim 24 further includes a coolant pump, the coolant pump being upstream of and fluidly connected to the cooling fluid inlet (52).

26. An electrically heated water system comprising a battery tower (18) according to any one of claims 1 to 20 and / or a battery pack (44) according to any one of claims 21 to 25.

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