RU2789348C2 - Rechargeable battery and method for manufacture of rechargeable battery - Google Patents

Abstract

FIELD: electrical engineering.

SUBSTANCE: invention relates to the field of electrical engineering, namely to a rechargeable battery and its manufacturing method, in particular to a rechargeable battery of a vehicle, having a thermal control system. The rechargeable battery contains one or several battery elements (30), flexible channel (50) located close to a surface of at least one or one of several elements (30), so that heat can be transferred between channel (50) and at least one or one of several elements (30), and a filling means, which at least partially surrounds at least part of channel (50). The method for the manufacture of a rechargeable battery includes provision of one or several battery elements (30), placement of flexible channel (50) close to the surface of at least one or one of several elements (30) in such a way that heat can be transferred between channel (50) and at least one or one of several elements (30), introduction of liquid into channel (50), and at least partial surrounding of at least part of channel (50) with the filling means. Expanding foam can be the filling means.

EFFECT: increase in a service life of a rechargeable battery due to minimization of temperature fluctuations inside the battery.

50 cl, 36 dwg

Description

The present invention relates to a battery and a method for manufacturing the same, in particular to a vehicle battery having a thermal management system.

Key requirements for next-generation batteries, especially lithium-ion batteries for vehicles, are improved gravimetric and volumetric energy density, extended life and fast charging. Gravimetric and volumetric energy densities have been greatly improved due to advances in battery cell electrochemistry and chemical engineering. However, improvements in the mechanical design of the battery also have a noticeable effect on the overall weight and size of the battery. The mechanical design of the battery affects the service life and ability to quickly charge, mainly due to the thermal management system. A thermal management system can be used to minimize temperature fluctuations within a battery to prevent differential aging of the cells, which will eventually lead to shortened battery life. In addition, it is important to maintain a relatively constant temperature of 25°C throughout the battery to maximize cell life. The latter is especially difficult to maintain during fast charging due to the strong heat generated inside the battery.

Thermal management systems in modern batteries usually include a heat exchanger in the form of a channel. The channel is a tube through which the cooling material can pass through the battery to cool or heat the individual cells of the battery. Flex channels are particularly useful as they are lightweight and can conform exactly to the shape of the elements when they are pressurized or inflated. However, a significant disadvantage of using flexible ducts is that they are prone to rupture: an increase in pressure inside the duct leads to stretching and thinning of the duct wall(s), which reduces the strength of the walls and potentially leaks the cooling medium inside the battery. While the risk of rupture can be reduced by increasing the thickness of the duct wall, this also increases the thermal resistance of the duct and therefore the efficiency of the thermal control system.

Another problem with modern battery packs is their tendency to ignite. The risk of fire inside a battery is increased when the cells are exposed to high temperatures, when short circuits occur, and/or when the internal structure of the cells is compromised. For example, lithium plating and/or crystal formation within a cell can pierce the cell's internal dielectric membranes, resulting in potentially catastrophic short circuits and cell explosion. Such an event can spread throughout the battery, causing all cells to ignite. There is a need for a method to stop or reduce the spread of excessive heat from a localized area within a battery.

The object of the invention is to eliminate or mitigate the problems described above. In particular, it is an object of the invention to provide a thin flexible duct for use in a thermal control system in which the duct has a reduced risk of rupture.

Yet another object of the invention is to provide a storage battery that is inherently flame retardant.

Another object of the invention is to provide a thermal control system which is in good thermal contact with one or more elements.

According to a first aspect of the invention, a rechargeable battery is provided, comprising: one or more battery cells; a flexible conduit located close to the surface of at least one or one of the plurality of elements so that heat can be transferred between the conduit and at least one or more elements; and a pouring means (compound) adapted to act as a support for at least a portion of the channel. Provides the advantage that the flexible conduit can closely conform to the shape of the surface of the cells within the battery while being reinforced with a potting agent that prevents excessive swelling and/or rupture of the flexible conduit.

If necessary, the battery contains a plurality of channels.

In a preferred embodiment, one or more channels are coils.

If necessary, one or more channels are collectors.

If necessary, the storage battery contains one or more mostly straight channels.

If necessary, the battery contains one or more parallel channels.

In a preferred embodiment, the single channel or each channel contains one or more generally straight sections.

In a preferred embodiment, a single channel or each channel is configured to supply a coolant.

In a preferred embodiment, a single channel or each channel is configured to pass a water-glycol mixture.

In a preferred embodiment, the implementation of the coolant is supplied under pressure in a single channel or in each channel to pressurize.

In a preferred embodiment, the single channel, or each channel, when inflated, corresponds to the surface of one or more elements. Provides the advantage that inflating the flexible conduit to match the shape of the elements improves thermal contact between the single or each conduit and the elements so that the coolant can more efficiently transfer heat energy between the coolant and the elements.

In a preferred embodiment, the shape of the single channel or each channel partially corresponds to at least part of the surface of one or more elements.

In a preferred embodiment, the battery cells are cylindrical cells. Provides the advantage that the flexible conduit is well suited for use with cylindrical elements because the conduit can expand and conform to the undulating surface of the cylindrical elements, providing good thermal contact between the elements and the conduit.

In a preferred embodiment, the battery contains an array of cells.

In the preferred embodiment, the array of elements is in a tightly packed configuration.

In a preferred embodiment, the minimum distance between elements is 0.5-5 mm.

In the preferred embodiment, the minimum distance between elements is 2 mm.

In a preferred embodiment, the flexible conduit is located adjacent to one or more elements.

In a preferred embodiment, the flexible conduit is located between the elements.

In a preferred embodiment, the implementation of the flexible channel is in direct contact with the side(s) surface(s) of a single or more elements.

In a preferred embodiment, the flexible conduit is in indirect contact with the side surface(s) of one or more elements via the mating region or mating material.

In a preferred embodiment, the flexible conduit is in indirect contact with the side surface(s) of one or more elements through the housing shell surrounding the element(s).

In a preferred embodiment, the flexible conduit is in indirect contact with the side surface(s) of one or more elements through a thermally conductive filler material such as a conductive paste or adhesive.

Ideally, the flexible duct is made from a polymer-based material.

In a preferred embodiment, the flexible conduit is made from an inflatable plastic. The inflatable plastic material provides an advantage because the material is inherently electrically insulating, lightweight, non-corrosive, and does not chemically interact with a coolant such as a mixture of glycol and water.

Ideally, the inflatable plastic material is low density polyethylene (LDPE).

Ideally, the inflatable plastic material is linear low density polyethylene (LLDPE).

Ideally, the inflatable plastic material is high density polyethylene (HDPE).

Ideally, the inflatable plastic material is polyester.

Ideally, the wall thickness of the flexible duct is between 10 µm and 150 µm. Provides the advantage that the inflatable plastic material can be very thin, which provides good heat transfer properties between a single or each of multiple channels and elements.

In a preferred embodiment, the flexible conduit is a single lumen conduit.

If necessary, the flexible duct can be multi-lumen. A multi-lumen duct can be used in large batteries where a single lumen duct is unable to provide uniform temperature distribution.

Ideally, the multi-lumen channel includes two or more lumen through which coolant can flow.

In a preferred embodiment, the battery includes a battery case.

In a preferred embodiment, the battery includes a bottom flap "shell".

In a preferred embodiment, the battery comprises a top shell.

In a preferred embodiment, the bottom flap and/or the top flap have one or more recesses for receiving and holding the element(s).

In a preferred embodiment, the bottom flap and/or the top flap have one or more openings for electrical connections to the elements.

In a preferred embodiment, one or more busbars are provided on the top and/or bottom sash.

In a preferred embodiment, the top flap and/or bottom flap comprise one or more openings for electrically connecting the element(s) to the busbar(s).

In a preferred embodiment, the battery contains one or more side walls.

In a preferred embodiment, one or more side walls are attached to the bottom flap.

In a preferred embodiment, one or more side walls are attached to the top flap.

In a preferred embodiment, the battery contains a fluid inlet.

In a preferred embodiment, the fluid inlet means allows fluid to enter a single channel or each of multiple channels.

In a preferred embodiment, the liquid inlet means has an inlet.

In a preferred embodiment, the battery contains means for releasing fluid.

In a preferred embodiment, the liquid outlet means has an outlet.

In a preferred embodiment, the liquid outlet means allows liquid to exit from a single channel or each of multiple channels.

In a preferred embodiment, the liquid inlet means and/or the liquid outlet means pass through openings in the side wall(s).

In a preferred embodiment, the battery contains at least one additional flexible channel located between the additional elements.

In a preferred embodiment, the potting agent for the compound includes potting material.

Ideally, the potting agent for the compound contains foam. Provides the advantage that the foam is lighter than other potting materials and therefore reduces the overall weight of the battery compared to other potting materials (compounds).

If desired, the potting agent for the compound includes thermosetting plastic, silicone rubber gel, or epoxy.

Ideally, the pouring means comprises thermally insulating foam.

Thermal insulation foam provides the advantage that it can prevent high energy thermal phenomena from propagating through the battery. In addition, thermal insulation foam can reduce the effect of fluctuations in external temperature on the battery and helps ensure the function of the channel as the main regulator of thermal energy inside the battery.

Ideally, the pouring agent comprises foam. Provides the advantage that the use of expanding foam within the battery means that the foam, when in an expanded state, can substantially fill any gaps within the battery. Combined with the thermal insulation properties of the foam, the ability of thermal phenomena to pass through the battery is greatly reduced.

Ideally, the pouring means includes intumescent foam.

Ideally, the filling medium is polyurethane foam.

Ideally, the pouring means acts as a support for at least a portion of at least one channel.

Ideally, the pouring means acts as a rigid support for at least a portion of at least one channel.

Ideally, the potting agent can be poured into the battery in a liquid state and will set, cure, or harden within the battery.

Ideally, the potting agent, in the cured, vulcanized or hardened state, is substantially rigid such that it locks the cell(s) and conduit(s) in place within the battery. Provides the benefit of reducing the impact of vibration on components inside the battery.

In a preferred embodiment, the fill means surrounds at least a portion of at least one channel.

In a preferred embodiment, the grouting means surrounds the channel and provides complete outer support for at least one channel. Provides the advantage that enclosing the duct with potting material prevents excessive expansion and/or rupture of the duct.

In a preferred embodiment, the pouring means forms a cavity in which at least a portion of at least one channel is located.

In a preferred embodiment, the volume within the battery case is substantially filled with cells, support structure, channel, and filler. Provides the advantage that substantial filling of the battery excludes moisture and/or corrosive substances from the space inside the battery.

In a preferred embodiment, the potting agent acts as an adhesive.

In a preferred embodiment, the potting agent acts as an adhesive to secure the channel or each channel in place.

In a preferred embodiment, the single channel or each channel has an open configuration so that the cooling material can pass through the channel.

In a preferred embodiment, the single channel or each channel is maintained in an open configuration by pressurized coolant within the single channel or each channel and/or by adhering to the filler.

In a preferred embodiment, the potting agent acts as an adhesive to maintain the single or multiple channels in an open configuration.

In a preferred embodiment, the potting means is attached with adhesive to at least a portion of one or more channels.

In a preferred embodiment, the potting agent acts as an adhesive to hold the element(s) in place.

In a preferred embodiment, the potting agent acts as an adhesive to attach the outer casing to the battery. Provides the benefit of eliminating the need for additional fasteners or fasteners, reducing battery complexity and improving the manufacturing process.

In a preferred embodiment, the battery contains at least one reference means configured to support at least one channel.

In a preferred embodiment, the single or each support means is placed on the bottom flap.

In a preferred embodiment, the single or multiple support means are located at the peripheral edge of the array of battery cells.

In a preferred embodiment, the single or each support means is configured to support the channel at the point where the channel turns and/or reverses direction. Provides the advantage that the support means prevents the channel from kinking at points where it changes direction. Kink prevention reduces system fouling, reduces system pressure loss, and improves coolant flow rate through channel(s).

In a preferred embodiment, the single or each support means comprises a guide channel.

Ideally, the guide channel is designed to guide the flexible channel.

In a preferred embodiment, at least a portion of the flexible conduit is located within the conduit of the support means. Positioning the flexible channel within the guide channel is advantageous because the guide channel guides the flexible channel at points where the channel changes direction, thus preventing kinks. In addition, the guide channel supports the flexible channel on both sides, which prevents it from swelling and potential rupture.

In a preferred embodiment, the support means comprises at least one recess configured to partially receive the channel in an uninflated state so that a slack is created in the channel. Provides the advantage of imparting excess slack to the canal to help prevent the canal from twisting when it is inflated. This is due to the fact that when the channel is inflated, it is under tension, and excess sagging helps to prevent the accumulation of excess stress in the channel.

In a preferred embodiment, the support means is configured to create a thermal barrier between the at least one element and the channel. This is useful because maintaining a constant temperature distribution across the battery is essential to prolong battery life. By insulating the cell at a location where there would be too much thermal contact between the duct and the cell, the thermal contact between the duct and the cells is kept substantially constant throughout the battery. This, in turn, contributes to a constant temperature distribution throughout the battery.

In a preferred embodiment, the battery is operatively linked to the thermal management system.

In a preferred embodiment, the thermal management system comprises a reservoir.

In a preferred embodiment, the reservoir is in fluid communication with the coolant circuit.

Ideally, the reservoir contains a coolant.

In a preferred embodiment, the reservoir provides hydrostatic pressure to the coolant in the coolant circuit.

In a preferred embodiment, the thermal management system comprises a pump configured to pump coolant from a reservoir into a coolant loop to pressurize the coolant loop. Provides the advantage that the coolant in the reservoir can be used to pressurize the thermal control system. Provides the advantage of being able to maintain pressure in the thermal control system while maintaining the pressure at the target operating level. Pressurizing the channel through the tanks makes it self-supporting, eliminating any hydrodynamic pressure loss from the pump and greatly reducing the pressure drop across the cooling system.

Ideally, the thermal management system includes a pressure sensor to monitor coolant pressure to maintain the target operating pressure.

In a preferred embodiment, the channel material comprises a matrix and a filler. Ideally, the thermal conductivity of the filler is greater than the thermal conductivity of the matrix. Provides the advantage that the inclusion of filler in the matrix increases the thermal conductivity of the channel material.

In a preferred embodiment, the matrix is a flexible matrix.

In a preferred embodiment, the matrix is electrically insulating.

In a preferred embodiment, the matrix is a plastic matrix.

In a preferred embodiment, the matrix is a polymeric matrix.

In a preferred embodiment, the matrix is a low density polyethylene (LDPE) matrix, a linear low density polyethylene (LLDPE) matrix, a high density polyethylene (HDPE) matrix, a polyester, silicone or rubber matrix.

In a preferred embodiment, the matrix has a thermal conductivity of less than 15 W-m ^-1 K ^-1 , less than 10 W-m ^-1 K ^-1 , less than 5 W-m ^-1 K ^-1 and (or) less than 1 W-m ^-1 K ^-1 .

In a preferred embodiment, the filler comprises particulate filler material.

In a preferred embodiment, the filler particles are dispersed throughout the matrix.

In a preferred embodiment, the filler particles have an average diameter of 1 nm to 10 µm.

In a preferred embodiment, the filler particles are elongated, tubular, fibrous, or generally spherical in shape.

In a preferred embodiment, the elongated filler particles have a diameter of 1-10 nm and optionally a length of 0.5-5 nm.

In a preferred embodiment, the filler comprises an organic filler material. In a preferred embodiment, the filler includes a carbon-based filler such as carbon, carbon black, graphite, graphite slabs, graphene, multi-walled carbon nanotubes, or single-walled carbon nanotubes.

Optionally, the filler includes an inorganic filler. Optionally, the filler includes a ceramic filler such as alumina, silicon carbide, boron nitride, silicon nitrate, alumina, aluminum nitride or zinc oxide.

In a preferred embodiment, the filler has a thermal conductivity greater than 10 Wm ^-1 K ^-1 and/or greater than 100 Wm ^-1 K ^-1 .

In a preferred embodiment, the channel material contains less than 25% filler by volume, 5-18% filler by volume, or 15% filler by volume. Provides the advantage that the inclusion of a limited amount of filler in the matrix allows for increased thermal conductivity while maintaining low electrical conductivity and suitable material flexibility.

In a preferred embodiment, the duct material has a thermal conductivity greater than 0.33 W-m ^-1 K ^-1 at room temperature, greater than 1 W-m ^-1 K ^-1 at room temperature, and/or greater than 10 W-m ^-1 K ^{- 1} at room temperature.

Ideally, the support means has an internal guiding formation.

Ideally, the inner guiding formation may be positioned on the inside of the coil of the flexible conduit during use.

In a preferred embodiment, the internal guide formation has an internal support surface that is positioned between the element and the flexible conduit during use.

Ideally, the support means has an outer guide formation, the outer guide formation having an outer bearing surface.

In a preferred embodiment, at least a portion of the guidance path of the support means is defined between the inner bearing surface of the inner guidance formation and the outer bearing surface of the outer guidance formation.

The inner bearing surface and/or the outer bearing surface may be continuous or discontinuous.

In a preferred embodiment, at least a portion of the support means is compressible. When inflated, the channel tends to pull in the direction of any kink within it due to tension. Provides the advantage that making at least part of the support means compressible allows the surface to which the channel pulls to yield slightly so that the volume of the channel does not overlap at the kink.

Ideally, the inner guide formation is compressible; in the most preferred embodiment, at least a portion of the inner bearing surface is compressible. Ideally, the inner guide formation contains a compressible foam material.

In a preferred embodiment, at least part of the support means is integral with the battery case. In the most preferred embodiment, at least a portion of the support means is integral with the lower battery case flap or the upper battery case shroud.

In a preferred embodiment, at least a portion of the battery case is integral to the support structure. In the most preferred embodiment, at least a portion of the inner sidewall of the battery case is used to support the flexible conduit.

According to a second aspect of the invention, a method for manufacturing a battery is provided, including: providing one or more cells; placing the flexible conduit close to the surface of at least one or more elements so that heat can be transferred between the conduit and at least one or more elements; introducing fluid into the channel; and providing a pouring means adapted to act as a support for at least a portion of the channel. Provides the advantage that the method provides for the manufacture of an improved battery, including a channel that can accurately match the shape of the surface of the cells and is reinforced with a filler.

In a preferred implementation, the method includes providing an array of elements.

In a preferred embodiment, the method includes providing one or more cylindrical elements.

In a preferred embodiment, the method includes creating an array of tightly packed cylindrical elements, in which the minimum distance between the elements is 0.5-5 mm.

In a preferred embodiment, the method includes creating an array of tightly packed cylindrical elements, in which the minimum distance between the elements is 2 mm.

In a preferred embodiment, the method includes constructing a battery case.

In a preferred embodiment, the method includes providing a bottom flap.

In a preferred embodiment, the method includes placing one or more elements in recesses in the bottom flap.

In a preferred embodiment, the method includes providing one or more side walls.

In a preferred embodiment, the method includes attaching one or more side walls to the bottom flap.

In a preferred embodiment, the method includes providing a top flap.

In a preferred embodiment, the method includes placing one or more elements in recesses in the top flap.

In a preferred embodiment, the method includes attaching one or more side walls to the top flap.

In a preferred embodiment, the method includes attaching one or more busbars to the top sash and/or bottom sash.

In a preferred embodiment, the method includes installing a liquid inlet in a single channel or in each of several channels.

In a preferred embodiment, the method includes installing a liquid outlet in a single channel or in each of several channels.

In a preferred embodiment, the method includes passing an inlet and an outlet through holes in the side wall(s).

In a preferred implementation, the method includes placing a single or each flexible channel next to one or more elements.

In a preferred embodiment, the method includes placing a single flexible conduit or each of multiple flexible conduits between elements.

In a preferred embodiment, the method includes placing one or more additional flexible channels close to the surface of one or more elements, so that heat can be transferred between the flexible channel or each additional flexible channel and at least one or more elements.

In a preferred embodiment, the step of placing the flexible channel(s) between the elements is performed after the step of placing one or more elements in recesses in the bottom flap.

In a preferred embodiment, the step of placing the flexible conduit(s) between two or more elements is performed prior to the step of placing one or more elements in recesses in the top flap.

In a preferred embodiment, the method includes placing the flexible conduit or each flexible conduit along a tortuous path within the battery.

In a preferred embodiment, the method includes placing the single channel or each channel close to the surface of at least one or more elements when the single channel or each channel is in a substantially uninflated state.

In a preferred embodiment, the step of introducing fluid into a single channel or each channel causes the channel(s) to expand.

In a preferred embodiment, the step of introducing fluid into the single channel or each channel comprises substantially filling the channel(s) with fluid.

In a preferred embodiment, the method includes inflating the channel(s) with liquid.

In a preferred embodiment, the method includes inflating the channel(s) with a working fluid such as air or coolant.

In a preferred embodiment, the step of introducing fluid into the single or each flexible conduit comprises pressurizing the conduit(s).

In a preferred embodiment, the step of introducing fluid into the single or each flexible conduit includes pressurizing the conduit(s) such that the fluid pressure in the conduit(s) is above atmospheric pressure.

In a preferred embodiment, the method includes inflating the single or each flexible channel so that the shape of the single or each channel matches at least a portion of the shape of the surface of one or more elements. Provides the advantage of increasing the thermal contact area between the duct and the cells, which improves the transfer of heat energy between the coolant in the duct and the individual battery cells.

Ideally, the method includes fixing one or more elements in place with the channel(s). Provides the advantage of eliminating the need for adhesive to hold the cells in place in the battery. Also, when the battery is used in the automotive or aerospace industry where it is subject to vibration, the conduit can reduce the effect of vibration on the battery by securing the individual cells in place.

In a preferred embodiment, the method includes placing one or more support means on the bottom flap.

In a preferred embodiment, the method includes placing one or more support means on the bottom flap at a peripheral edge of the array of elements.

In a preferred embodiment, the method includes placing a portion of the channel within the support means to support at least a portion of the channel. The placement of the channel in the support means is advantageous because it prevents the channel from bending when the channel is expanded.

In a preferred embodiment, the method includes placing a portion of the conduit within a recess in the support means when the conduit is in a substantially uninflated state. Provides the advantage of locating the channel in a recess, thereby providing excess sag in the channel before it is inflated. Providing excessive channel sag reduces channel twisting during the inflation process.

In a preferred embodiment, the method includes surrounding at least a portion of one or more channels with a fill.

In a preferred embodiment, the method includes surrounding essentially a single channel or each channel in its entirety with a fill.

In a preferred embodiment, the method includes introducing the pouring agent through the top flap, bottom flap and/or side wall(s).

In a preferred embodiment, the method includes introducing an expandable primer into the battery.

In a preferred embodiment, the method includes performing a pressure test on the flexible conduit prior to introducing the primer into the battery.

In a preferred embodiment, the method includes injecting the foam into the battery.

In a preferred embodiment, the method includes introducing intumescent foam into the battery.

In a preferred embodiment, the method includes injecting polyurethane foam into the battery.

In a preferred embodiment, the method includes injecting a thermosetting plastic, silicone rubber gel, or epoxy resin into the battery.

In a preferred embodiment, the method includes introducing a primer into the battery.

In a preferred embodiment, the method includes inserting the primer into the battery when the primer is in a viscous or liquid state.

In a preferred embodiment, the method includes injecting liquid into a single channel or each channel before introducing the primer into the battery.

In a preferred embodiment, the method includes pressurizing and/or inflating a single flexible conduit or each flexible conduit prior to introducing the primer into the battery.

In a preferred embodiment, the method includes curing or curing the potting agent within the battery.

In a preferred embodiment, the step of introducing liquid into a single flexible conduit or each flexible conduit causes the conduit(s) to expand into an open configuration.

In a preferred embodiment, the method includes maintaining, by adhering to the filler, a single channel or each of multiple channels in an open configuration within the battery.

In a preferred embodiment, the method includes curing or curing the filler within the battery when the single channel or each channel is in a substantially inflated state and/or in an open configuration.

Ideally, the method includes maintaining pressure within a single channel, or each of multiple channels, until the pouring means solidify or solidify and enter a substantially rigid state. Provides the advantage that inflating the channel before inflating the priming agent allows sufficient space in the channel to expand after the priming agent has become rigid.

In a preferred embodiment, the method includes expanding the filling means to fill gaps within the battery. Provides the advantage that the expansion of the foam means that it fills any gaps inside the battery. This improves the overall mechanical strength of the battery.

In a preferred embodiment, the method includes insulating the elements by surrounding the elements with thermally insulating foam. Provides the advantage that the thermal insulation foam can prevent the high energy thermal phenomenon from propagating through the battery. In addition, thermal insulation foam can reduce the effect of fluctuations in external temperature on the battery and helps ensure the function of the channel as the main regulator of thermal energy inside the battery.

In a preferred embodiment, the method includes securing, with a potting agent, the conduit and/or cells in place within the battery.

In a preferred embodiment, the method includes maintaining, by adhering to the primer, a single or each channel in an open configuration within the battery.

In a preferred embodiment, the method includes attaching, by means of a potting agent, the outer case to the battery. Provides the benefit of eliminating the need for additional fasteners or fasteners, reducing battery complexity and improving the manufacturing process.

In a preferred embodiment, the method includes electrically connecting the battery cells to the rails.

In a preferred embodiment, the method includes electrically connecting the elements to the busbars using ultrasonic welding, laser welding, ultrasonic welding, or resistance welding.

In a preferred embodiment, the method includes electrically connecting the elements to the rails while the elements are held in place by a flexible conduit.

In a preferred embodiment, the method includes electrically connecting the cells to the rails before the potting material is introduced into the battery.

In a preferred embodiment, the method includes introducing the filler into the battery after the cells are electrically connected to the tires. Provides the advantage that the potting agent serves to protect the aluminum ultrasonic wire connections from external moisture, thereby preventing galvanic corrosion of the wire connections.

In accordance with a further aspect of the present invention, a method is provided for electrically connecting an element to a tire, the method comprising: holding the element in a desired position using an inflated flexible conduit; and providing an electrical connection between the element and the bus. Provides the advantage that the flexible conduit can secure the cell(s) in place within the battery, eliminating the need for adhesive when electrically connecting the cell(s) to the busbar(s).

In a preferred embodiment, the step of providing an electrical connection between the element and the busbar includes ultrasonic connection of the wire to the element and/or busbar.

In a preferred embodiment, the step of providing an electrical connection between the element and the busbar includes ultrasonic bonding, laser welding, ultrasonic welding, or resistance welding.

In a preferred embodiment, the step of providing an electrical connection between the element and the busbar includes connecting an aluminum wire to the element and/or busbar.

In a preferred embodiment, the method includes pouring at least one element after ultrasonic connection of the elements to the busbars.

It should be understood that additional features applicable to one aspect of the invention may be used in any combination and in any amount. Moreover, they can also be used with any of the other aspects of the invention in any combination and in any amount. This includes, without limitation, dependent claims from any claim used as dependent claims for any other claim of this application.

The invention will now be described with reference to the accompanying drawings, in which, by way of example, only one embodiment of a device according to the invention is shown.

Rice. 1 is a schematic diagram of a thermal management system and control module suitable for use with a battery in accordance with the invention.

Rice. 2 is a perspective view of a storage battery provided with top and bottom flaps and side walls.

Rice. 3 is a perspective view of the storage battery shown in FIG. 2 with the side walls removed.

Rice. 4 is a perspective view of the bottom component of the battery door shown in FIG. 2.

Rice. 5 is a perspective view of the bottom flap of fig. 4 provided with an array of elements.

Rice. 6 is an enlarged perspective view showing the element array of FIG. 5 equipped with a thermistor.

Rice. 7 is an enlarged perspective view showing the support structure mounted on the element array shown in FIG. 5.

Rice. 8 is a perspective view of a support structure suitable for use with embodiments of the invention.

Rice. 9 is a perspective view of a flexible conduit being attached to the element array shown in fig. 5.

Rice. 10 is a perspective view of a multi-lumen flexible conduit suitable for use with embodiments of the invention.

Rice. 11 is a plan view of a heat exchanger containing a plurality of flexible ducts suitable for use with embodiments of the invention.

Rice. 12 is a perspective view of the heat exchanger shown in fig. eleven.

Rice. 13 is a plan view of a heat exchanger containing a plurality of flexible multi-lumen passages suitable for use with embodiments of the invention.

Rice. 14 is a perspective view of the heat exchanger shown in fig. 13.

Rice. 15 is a plan view of a heat exchanger containing a plurality of flexible multi-lumen passages suitable for use with embodiments of the invention.

Rice. 16 is a perspective view of the heat exchanger shown in fig. 15.

Rice. 17 is a perspective view of a storage battery provided with top and bottom flaps, side walls and a boost manifold.

Rice. 18 is a sectional view of a flexible conduit located between battery cells in an uninflated state.

Rice. 19 is a sectional view of a flexible conduit located between the cells of an inflated battery.

Rice. 20 is an enlarged plan view of the support structure and flexible conduit in an uninflated state.

Rice. 21 is an enlarged plan view of the support structure and flexible conduit in place.

Rice. 22 is an enlarged plan view of the support structure and flexible conduit in an inflated state.

Rice. 23 is a perspective view of a battery filled with potting material in an automated process.

Rice. 24 is a schematic diagram of a thermal management system suitable for use with tank embodiments.

Rice. 25 is a schematic diagram of the thermal control system shown in fig. 24, under pressure.

Rice. 26 is a schematic diagram of the thermal control system shown in fig. 24, in working order.

Rice. 27 is a schematic diagram of an alternative thermal management system suitable for use with embodiments of the invention.

Rice. 28 is a plan view of the element array and the serpentine channel with the channel wall thickness varying along the length of the channel.

Rice. 29 is a perspective view of a plurality of straight channels with channel wall thickness varying along the length of the channels.

Rice. 30 is a perspective view with a section of a battery pack showing potting material.

Rice. 31 is a schematic cross-sectional view of a channel in which the channel material comprises a matrix and filler.

Rice. 32 is a perspective view of the additional support structure.

Rice. 33 is a plan view of the support structure shown in fig. 32.

Rice. 34 is a perspective view of the additional support structure.

Rice. 35 is a perspective view of the support structure shown in FIG. 34 installed inside the battery.

Rice. 36 is an additional perspective view of the support structure of FIG. 35 installed inside the battery.

On fig. 1 shows a thermal management system 18 for a storage battery 21. The term "battery" is used here to describe one or more individual electrochemical cells, such as a group of cells arranged in an array. The term "cell" may be used to refer to any form of electrochemical cell, including but not limited to lithium ion or nickel metal hydride cells. The storage battery 21 comprises one or more elements 30, a flexible conduit 50/230 located close to the surface of at least one or more elements 30 so that heat can be transferred between the flexible conduit 50/230 and at least one or more elements 30, and a potting material (compound) 231 adapted to act as a support for at least a portion of the channel 50/230. Any number of individual cells can be used to create the desired voltage and capacity of the storage battery 21.

The thermal management system 18 is used to manage the thermal energy in the storage battery 21 in order to maintain the individual cells at the appropriate operating temperature, for example around 25°C. The individual cells in the battery 21 generate heat as they are charged and/or discharged. Thermal management system 18 controls the thermal energy in battery 21 by circulating a coolant, such as a mixture of glycol and water, through a flexible channel that is close to the surface and/or in contact with individual cells.

The thermal control system 18 includes a heat exchanger 23, a pump 25, and a flexible conduit (not shown) through which coolant passes through the battery 21. The flexible conduit is in fluid communication with the heat exchanger 23 and pump 25 as part of the same coolant circuit 183. Coolant in the system thermostat 18 is pressurized and pump 25 causes coolant to flow through coolant loop 183. The coolant pressure causes the flexible conduit to expand. As the flexible conduit expands, it conforms to the undulating surface represented by the shape of the cylindrical elements, thereby increasing the surface area of the flexible conduit that is in contact with each of the cylindrical elements. This provides the advantage of increasing the thermal contact area and contact pressure between the elements and the flexible conduit, as well as improving the transfer of thermal energy between the flexible conduit and the individual elements.

By adjusting the coolant flow in the flexible conduit, the pump 25 is adjusted to maintain the temperature of the battery 21 at the desired operating temperature. The heat exchanger 23 can dissipate heat energy from the coolant when the battery 21 requires cooling. The heat exchanger 23 can add thermal energy to the coolant when the battery 21 requires heating. An additional heating or cooling system may interact with the heat exchanger 23 as needed.

The thermal control system 18 is connected to the control module 27. The control module 27 receives input signals indicative of the temperature inside the battery 21. The control module 27 can output a control signal to the thermal control system 18 to adjust the thermal control system 18 in response to the received temperature inputs, whereby the desired operating temperature is maintained.

Battery 21 comprises an array or matrix of cylindrical elements 30. The elements 30 are sandwiched between lower and upper flaps 20, 80, which are connected by peripheral side walls 90, 92 shown in FIG. 2. In fig. 3 shows a battery with a number of components (including sidewalls 90, 92) so that the cells 30 inside the battery can be seen. The elements 30 are centered along parallel axes and arranged in an array of straight parallel rows. The lower and upper flaps 20, 80 include busbars that electrically connect the individual elements 30 and constitute the battery 21.

The skilled reader will appreciate that the elements may be non-cylindrical, such as cuboid, prismatic, or stacked elements. However, cylindrical cells have a relatively low cost and high energy density, making them an attractive choice for battery applications. In addition, cylindrical elements are easier to mass-produce than other shaped elements such as stack elements or cube elements, and are self-supporting (pack elements require a holder or support, while prismatic elements are also self-supporting). In the implementation examples, the cells are 18650 or 2170 Li-Ion cells.

On fig. 4 shows a perspective view of the bottom flap 20 of the battery 21. The bottom flap 20 is a plate with an array of notches in the form of round sockets 22. receiving the end portion of the respective cylindrical element 30. In the example shown, the sockets 22 are arranged in an array with sixteen parallel rows, each row being thirteen sockets long. The sockets 22 of each row are staggered with respect to the sockets of an adjacent row or rows such that each of the sockets 22 is nested between a pair of sockets 22 of one or two adjacent rows. This maximizes space efficiency and power density, but makes it difficult to maintain the correct operating temperature of the cells 30.

The skilled reader will appreciate that any number of rows of cells of any suitable length may be used in battery 21. Increasing the number of individual cells 30 in battery 21 increases the overall capacity and/or voltage of battery 21. In addition, cells 30 in battery 21 may be arranged vertically in a vertically stacked battery.

The manufacture of the battery 21 involves the use of one or more cells 30, such as the array of cells shown in FIG. 5. In an exemplary embodiment, a plurality of elements 30 are inserted into respective sockets 22 of the bottom sash 20. The elements 30 are located adjacent to the sockets 22, and busbars located on the underside of the bottom sash 20 (not shown) are connected to individual elements 30.

Many battery cell manufacturers recommend a minimum distance of 2 mm between cells to prevent heat transfer. The skilled reader will appreciate that a tightly packed, staggered array of cylindrical elements is the most volumetrically efficient way of stacking cylindrical elements in a given volume while maintaining the minimum recommended spacing between elements. The flexible conduit 50 described herein has walls 10 to 150 µm thick, and the conduit 50 can easily fit in a 2 mm staggered conduit between adjacent cylindrical members 30. Prior art thermal management systems generally require increased spacing between members to accommodate the conduit, which increases the overall size of the battery and reduces the volumetric energy density. The present invention offers a significant improvement over the prior art in this regard. In addition, the present invention allows adjacent elements 30 to be separated by the minimum gap recommended by the element manufacturers, or any minimum gap in the range of 0.5-5 mm.

On fig. 6 shows how temperature sensors 40, such as a set of thermistors, can be connected to suitably pitched cells 30 in battery 21. During assembly, a cable 42 attached to temperature sensor 40 is left loose. This is so that the cable 42 can be attached to the upper shutter 80 when the upper shutter 80 is attached to the battery pack 21. The temperature sensors 40 monitor the temperature of the individual cells 30 in the battery 21 and report the temperature readings to the control module 27. If the temperature of the cells 30 deviates from the target operating temperature, the control module 27 may adjust the thermal management system 18 to maintain the target operating temperature.

As the skilled reader will appreciate, the present invention can be used in batteries that typically use straight, parallel, manifold and/or serpentine heat exchangers/ducts. Serpentine channels are commonly used with prismatic elements because the flat surfaces of the prismatic elements provide a large surface area for thermal contact with the channel. Wrapping the flexible conduit around the prismatic elements in a serpentine fashion, thus maintaining thermal contact, is not difficult. However, serpentine channels are subject to kinks at kink points where the direction of the channel is reversed or reversed. A kinked heat exchanger can cause plugging and pressurization of the duct, which can obstruct or prevent coolant flow. The kink causes the flexible conduit 50 to fold inward on itself, which can lead to blockage within the conduit 50. Pressure losses in the system due to the kink in a series of multiple kinks can be significant, reducing the overall performance of the thermal control system 18. In addition, pressure build-up can lead to stretching and thinning of the channel wall, which can eventually lead to rupture and loss of coolant.

Kink blockages can be overcome by pressurizing the coolant inside the passage 50 to a sufficient level that causes the flexible passage 50 to open even at bends. However, the use of high pressure to overcome the kink can cause the flexible conduit 50 to stretch, thin, and rupture. The pressure required to overcome the kinks at each bend of the flexible conduit 50 often exceeds the pressure that the flexible conduit 50 can withstand without rupture.

In embodiments where flexible conduit 50 is to follow a tortuous path between and/or around cells 30 in battery 21, there must be a way to securely support conduit 50 at the corners to prevent it from kinking and/or breaking. As shown in fig. 7, support structures 70 are used in battery 21 as guides at locations where flexible conduit 50 changes direction, i.e., where it tends to kink. The support structures 70 are located at the edge of the battery 21 where the flexible conduit 50 exits the cell array 30 and reverses direction. On fig. 7 shows support structures 70 located on battery 21 at the periphery of cells 30. Support structures 70 are located along opposite sides of battery 21 at each point where conduit 50 exits and re-enters cell array 30.

Appropriate support structures 70 are located on opposite sides of the battery 21 to guide the flexible conduit 50 where the flexible conduit 50 exits the cell array 30 and changes direction. For this purpose, as shown in Fig. 8, support structure 70 defines a guide path 74 for flexible conduit 50. Guide path 74 is a slot or groove into which flexible conduit 50 can be inserted and followed by flexible conduit 50 to change direction without kinking. The guide path 74 of the support structure 70 is defined between the inner bearing surface 77 of the inner guide formation 72 and the outer bearing surface 78 of the outer guide formation 79.

Flexible conduit 50 may be inserted into support structure 70 in an uninflated state to follow guide path 74. Guide conduit 74 is shaped to accommodate excess length of flexible conduit 50. Providing excess length of flexible conduit 50 creates some sag that reduces kink when flexible. the channel 50 is inflated and thus stressed. The flexible conduit 50 is inserted into the guide 74 in an uninflated state to facilitate assembly. However, the skilled reader will appreciate that a small amount of working fluid can be used to pressurize the flexible conduit 50 to stiffen the flexible conduit 50 for ease of assembly. The working fluid can be, for example, air or coolant.

The inner guiding formation 72 is sized such that the radius of curvature of the inner bearing surface 77 is large enough to smoothly guide the flexible conduit 50 through 180° in successive 90° bends without kinking the conduit 50. As shown in FIG. 8, the inner support surface 77 includes a flat elongated edge 73 between two rounded edges 75. The elongated edge 73 serves to straighten and support the flexible conduit 50 at a point where a kink would otherwise be most likely.

Notch recesses 76 in the outer guide formation 79 against the rounded edges 75 form part of the outer bearing surface 78 to accommodate the sag defined by the excess length of the flexible conduit 50. In particular, the camber portions of the flexible conduit 50 around the rounded edges 75 can be pulled or pushed away from the rounded edges. edges 75 and guide into the recesses 76. Pressing the flexible conduit 50 into the 35 recesses 76 in this manner before inflating the flexible conduit 50 creates slack in the flexible conduit 50 on the rounded edges 75. Allowing this slack in the flexible conduit 50 prior to inflation is beneficial as it helps to reduce kinking of the conduit 50 when inflated. The notch recesses 76 are recesses in the outer bearing surface 78 of the outer guide formation 79 and may be of any shape suitable to partially receive the channel 50 to create sag around the rounded edges 75.

As the skilled reader will appreciate, if battery 21 does not have significant kinks and/or kink is unlikely (eg, when a non-serpentine or typically straight channel is used), then support structures are generally not required.

The fabrication of battery 21 includes placing flexible conduit 50 close to the surface of at least one or more cells 30 so that heat can be transferred between flexible conduit 50 and at least one or more cells 30. FIG. 9 shows a flexible conduit 50 being inserted into an array of cells 30. Conduit 50 is positioned in a serpentine fashion within battery 21 so that coolant 20 flows through battery 21. In particular, conduit 50 has a series of generally straight sections that extend between adjacent rows of cells. 30. The straight sections of the channel 50 alternate with bends where the channel 50 exits the array of elements 30 and changes direction to pass along and between the next pair of rows of elements 30.

The serpentine arrangement of the flexible conduit 50 ensures that the flexible conduit 50 is in thermal contact with all the cells 30 in the battery 21. The flexible conduit 50 may, for example, be an inflatable band of plastic material such as polyester, LDPE, LLDPE, HDPE, any other plastic a material or polymer-based material that is flexible and capable of withstanding coolant pressure. The inflatable plastic material is beneficial because the material is inherently electrically insulating, lightweight, and does not corrode or chemically interact with a coolant such as a mixture of glycol and water.

Flexible conduit 50 is provided with an inlet 52 and outlet 54. In use, inlet 52 and outlet 54 are connected to a pump 25. Pump 25 is configured to create a coolant flow within flexible conduit 50 such that coolant flows through flexible conduit 50. liquid in the thermal control system 18 to a pressure above atmospheric pressure causes the flexible channel 50 to expand and take the form of cylindrical elements 30. Details on how the coolant is supplied under pressure are given in the description below.

As best seen in Fig. 9, the pipes are connected to the flexible conduit at the inlet 52 and outlet 54, respectively. The conduits are configured to connect to the coolant circuit 183 of the thermal management system 18 so that the coolant can move through the thermal management system 18. The area of the flexible conduit 50 connected to the inlet and outlet conduits can be reinforced to prevent rupture or excessive expansion of the conduit 50. The conduit 50 can be reinforced by making the end of conduit 50 of a stronger plastic material, or by providing an outer sleeve of material over flexible conduit 50 to prevent expansion of flexible conduit 50 at inlet 52 or outlet 54.

Channel 50 shown in fig. 9 is a single lumen expandable channel 50. However, as shown in FIG. 10, a multi-lumen expandable conduit 223 can be used in the thermal management system 18. The multi-lumen conduit 223 includes an inlet 221 and an outlet 220. The inlet 221 and outlet 220 are configured to pass coolant through the battery 21. This is useful for use in large batteries 21 because it improves the distribution of thermal energy throughout the battery 21. In large batteries 21, the single lumen channel 50 may not be able to provide sufficient cooling or heating to the elements 30 located downstream in the channel 50. This problem is solved by using a multi-lumen channel 223, which provides a more uniform temperature distribution in the battery 21.

The multilumen channel 223 is made from the same plastic as the single lumen channel 50. To create the multilumen channel 223, a seal 222 is formed between the inlet and outlet passages 221, 220. The seal 222 can be created by melting the plastic material of the channel 223 to create a connection. The operation of the multi-lumen passage 223 is essentially the same as that of the single-lumen passage 50, except that the multi-lumen passage has bi-directional coolant flow. The multi-lumen channel 223 may be positioned within the support structure 70 in a manner similar to the single-lumen channel 50. In addition, the multi-lumen channel 223 may be pressurized with coolant, as described above, so that the channel 223 expands in accordance with the shape of the surface of the elements 30. duct 223, as the skilled reader will appreciate, a manifold will be located at the end of duct 223 opposite the inlet to duct 223. The manifold will allow coolant to flow from inlet 221 to outlet 220, thereby facilitating bidirectional flow of coolant in duct 223.

Although in the embodiment shown in Fig. 9, a serpentine channel 50 is used, the skilled artisan will appreciate that other channel geometries are possible and may be used to practice the invention. On fig. 11 and 12 show a plurality of generally straight single lumen channels 550 in their expanded state (elements not shown for clarity). Each of the individual direct channels 550 is connected through the input 552 and output 554 and must be located between adjacent rows of elements. On fig. 13 and 14 show a plurality of generally straight, multi-lumen channels 650 in their expanded state (batteries not shown for clarity). The first lumen of each channel 650 is connected to the inlet 652 and the outlet 654. The second lumen of each channel 650 is connected to the inlet 651 and the outlet 653. In fig. 15 and 16 show a plurality of generally straight, multi-lumen channels 750 in an expanded state (elements not shown for clarity). Each of the individual direct channels 750 is connected through the input 752 and output 754 and must be located between adjacent rows of elements. The gaps in each of the straight channels 750 are connected at the end of the channel 750, which is opposite the entrance and exit.

Returning to the embodiment shown in Fig. 9, once the flexible conduit 50 is in place within the battery 21 and between/near the cells 30, the battery case is completed. The housing comprises bottom and top flaps 20, 80 which are connected by four peripheral side walls, including the side walls 90, 92 shown in FIG. 17. The side wall 92 includes two openings corresponding to the inlet 52 and outlet 54 of the flexible conduit 50. The inlet 52 and outlet 54 are aligned with the corresponding holes in the side wall 92 so that the flexible conduit 50 can be connected to the pump 25 and the heat exchanger 23 of the thermal control system 18 .

As will be appreciated by the skilled artisan, one or more side walls 90, 92 may be attached to the bottom flap 20 before the elements 30 are inserted into the respective sockets 22 of the bottom flap 20 and/or the flexible conduit 50 is inserted between and around the elements 30. them.

The top flap 80 is placed over the array of cells 30 in the battery 21 after the flexible conduit 50 has been placed as described above. Busbars (not shown) are located within the recesses 82 on top of the upper shutter 80 for electrical connection of individual elements 30. The aforementioned wires 42, connected to thermistors 40, pass through the upper shutter 80 and pass through the grooves 84 located on the upper surface of the upper shutter 80.

As shown in fig. 17, pressure manifold 100 is connected to flexible conduit 50 of battery 21 through inlet 52 and outlet 54. Check valves 101 operate between pressure manifold 100 and inlet 52 and outlet 54. Pressure manifold 100 pressurizes flexible conduit 50. by introducing a working fluid, such as air, into the flexible conduit 50 at a pressure above ambient. For example, the pressure supply manifold 100 pressurizes the flexible conduit 50 by 0.5 to 1.5 bar during the assembly process. This causes the flexible conduit 50 to expand to an inflated state.

Pressurizing the flexible conduit 50 in this way causes the conduit 50 to expand and take on the shape of the elements 30 and in particular the waveform of the rows of elements 30. The pressure in the flexible conduit 50 can be controlled for a predetermined period of time during the manufacturing process to ensure there are no leaks in the flexible channel 50.

During assembly, shut-off valves 101 may be closed and pressure manifold 100 removed from battery 21. This is advantageous because assembly of battery 21 can be continued with flexible conduit 50 inflated. It is expedient to carry out the steps of attaching the battery 21 and adding potting material to the battery 21 when the flexible conduit 50 is in the expanded state. This is because the duct 50 holds the elements 30 in their position when in the expanded state (as discussed below), and also because the addition of potting material when the flex duct 50 is in the non-expanded state will prevent subsequent inflation of the duct. 50.

On fig. 18 shows flexible conduit 50 in an unexpanded state when inserted into battery 21 between adjacent rows of cells 30. Flexible conduit 50 is generally straight in the unexpanded state so that the area of contact between flexible conduit 50 and each cell 30 is relatively small, being substantially tangent to the surface of the element and extending in a narrow strip along each element 30 without significant circumferential elongation.

On fig. 19 shows flexible conduit 50 in an expanded operational state. When the flexible conduit 50 is pressurized with working fluid prior to use or coolant during use, the flexible conduit 50 expands and undulates into rows of members 30. As can be seen in FIG. 19, in the expanded state, the flexible conduit 50 more closely conforms to the shape of the individual elements 30, thereby increasing the area of thermal contact between the conduit 50 and the elements 30. The compressed coolant within the conduit 50 also increases the contact pressure between the conduit and each individual element 30, improving thermal coupling. between them. In addition, the collision of natural flows causes a strong mixing of the coolant flows inside the channel 50.

On fig. 20 shows the flexible conduit 50 in an uninflated state located within the guide track 74 of the support structure 70. FIG. 21 shows the sagging of the flexible conduit inserted into the recesses 76. In fig. 22 shows the flexible conduit 50 in an inflated state within the support structure 70 and members 30.

When first installing flexible conduit 50 inside track 74, an elongated rod or tool 120 can be used to position flexible conduit 50 within recesses 76, as shown in FIG. 21. An elongated rod or tool 120 pushes the flexible conduit 50 into the recess 76 so that a slack is created in the flexible conduit 50. In particular, sag is created in the region of the rounded edges 75 so that when the duct 50 is inflated, thereby being subjected to tension, the duct 50 does not bend.

When conduit 50 is inflated, tension in conduit 50 eliminates any excess slack in conduit 50. As excess slack in conduit 50 is eliminated, conduit 50 is pulled out of recessed grooves 76 as shown in FIG. 22. When inflated, the channel 50 contacts the rounded edges 75 on the inner support surface 77 and is supported by an elongated edge 73.

The support structure 70 is sized such that the elements 130 located at the end of each row of the array have substantially the same area of thermal contact with the channel 50 as the elements 30 located at the center of the array. This is advantageous as it promotes a more uniform temperature distribution in the battery 21, thereby prolonging the service life of the battery 21. The support structure 70 achieves this by shielding or thermally insulating a portion of the end members 130 from thermal contact with the conduit 50 so that the conduit 50 has essentially the same area of thermal contact with the end elements 130 as the elements 30 located inside the array.

As shown in fig. 20-22, the ends of the outer support surface 78 abut the end members 130 such that the outward curvature of the guide path 74 is defined by the outer support surface 78 from the point at which the channel 50 exits the array to the point at which the channel 50 re-enters the array. . The outer support surface 78 prevents the channel 50 from expanding so that it surrounds the outside of the elements 130, which will cause increased thermal contact of the end member 130 with the channel 50.

Similarly, one end of the inner support surface 77 abuts against the end member 130. The end of the inner support surface 77 that abuts against the end member 130 provides support to the channel 50, thereby preventing the channel 50 from protruding and wrapping around the end member 130. The other end portion 110 of the inner support surface 77 partially follows the surface of the other end element 130 so that the end portion 110 wraps around the end element 130, forming a thermal barrier. The end portion 110 of the inner support surface 77 partially wraps around the outer surface of the end member 130 so that when the bore 50 is positioned within the guide path 74, the bore 50 does not contact the end member 130 in the region of the end portion 110. The skilled reader will appreciate that the extent to which which portion 110 extends around end member 130 depends on thermal contact between channel 50 and members 30. Portion 110 extends around end member 130 sufficiently to ensure that channel 50 is no more in contact with end member 130 than with any other member 30 in array.

The support structure 70 serves to reduce channel 50 kink at the points where channel 50 exits the array and reverses direction. The guide path 74 defines a track for channel 50 to follow from the point where channel 50 exits the array to the point where channel 50 re-enters the array. The guide path 74 prevents excessive swelling and/or rupture of the channel 50.

The sockets 22 on the bottom and top flaps 20, 80 are sized to provide a clearance fit with respect to the individual elements 30. This is advantageous because it allows the individual elements 30 to be easily placed in the sockets 22 using an automated manufacturing process; however, the cells 30 can move in their respective seats 22, which is undesirable when connecting the battery 21 using, for example, ultrasonic wire bonding to connect the cells 30 to the busbars. This is because both the elements and the busbars must be mechanically rigid for the ultrasonic wire welding process to create a high quality electrical connection between them. To solve this problem, it is known in the prior art to glue the individual elements 30 in such a position as to provide a strong mechanical connection between the individual elements 30 and the lower and upper flaps 20, 80. However, this is an additional and inefficient step in the manufacturing process. Pressurizing the flexible conduit 50 not only causes the flexible conduit 50 to expand and take the shape of the individual elements 30, but also locks the individual elements 30 into the sockets 22. Thus, the inflated flexible conduit 50 can be used to secure the element(s) 30 in place when formed. the electrical connection between the element(s) and the busbar(s). The fixation of the elements 30 in the desired position by means of the inflated channel 50 eliminates the need to glue individual elements 30 in position on the sash 20, 80.

Individual elements 30 may be connected using an automated ultrasonic wire bonding process. This process is performed on both the bottom and top flaps 20, 80. The skilled artisan will appreciate that the individual elements 30 may be attached using any other suitable process. In addition, the control module 27 is connected to the busbars at this stage of the assembly process. The built-in electronic test of the battery 21 can be performed at this stage of the assembly process as a quality assurance step to ensure that the connections have been made correctly before continuing with the assembly process. It is desirable to perform the wire connection process while the flexible conduit 50 is in the expanded state so that the individual members 30 are locked into place, as this improves the quality of the connection. In addition, the potting material serves to protect the aluminum ultrasonic wire connections from external moisture, thereby preventing galvanic corrosion of the wire connections.

The fabrication of the battery 21 includes providing a potting material adapted to act as a support for at least a portion of the conduit 50. In a preferred embodiment, the potting material is an intumescent foam such as expanding polyurethane foam, although other potting materials such as thermosetting plastic can be used. , silicone rubber gel or epoxy.

The potting material is introduced into the battery 21 in a liquid or viscous state after the assembly of the case is completed and after the wire connection is completed. In the case of an expandable potting material, such as intumescent foam, the expandable potting material expands to fill the gaps within the battery 21 so that the flexible conduit 50 and individual cells 30 are surrounded by the potting material. Upon full expansion, the volume within the battery case is substantially filled with the elements 30, support structures 70, conduit 50, and filler. The expandable potting material expands from a liquid state and becomes rigid upon injection so that it can dampen and/or prevent the spread of heat throughout the battery 21. The expandable potting material may be a polyurethane foam that is designed to char when exposed to high temperatures, for example up to 1000 °C. This is advantageous because the charred pure carbon layer acts as an excellent heat insulator, thereby preventing the high energy thermal phenomenon from spreading through the battery 21. Thus, the battery is flame resistant.

The fill material is introduced into the battery 21 when the channel 50 is inflated. The fill material solidifies around the inflated channel 50 so that a cavity is formed within the fill material, within which the channel 50 is located. The cavity provides full external support to the channel 50, thereby preventing excessive inflation and/or rupture of the channel 50. The fill material becomes generally rigid, to secure channel 50 in position, and also acts as an external support for channel 50, providing mechanical support to channel 50. Polyurethane foam has the advantage of being extremely light due to its high air content compared to other potting materials such as water-based gels. base or silicone gels.

After the potting material vulcanizes or cures, the single channel or each channel 50 is maintained in its open configuration by adhering to the potting material. This means that the working fluid can be removed from inside the channel 50, and the channel, despite this, will remain in its open configuration.

The use of a potting material such as foam within the battery 21 also thermally insulates the battery 21 from the outside. This is useful because it means that the thermal management system 18 is a significant temperature controller of the battery 21 (as opposed to environmental factors), simplifying the overall control of the thermal management system 18. Insulating the battery 21 improves the thermal "endurance" of the battery 21, reducing the need for periodic cooling. of the battery 21 when the battery 21 is not used in a stable low or high temperature environment. The foam within the battery 21 also provides increased vibration protection and mechanical protection for the internal components of the battery 21. The foam hardens, which means that it serves to lock the cells 30 and the flexible conduit 50 in position within the battery 21. This is especially advantageous in the case of automotive applications where the battery 21 is subjected to periods of continuous vibration.

On fig. 23 shows an accumulator 21 into which pouring material is introduced. The potting material may be introduced into the battery pack 21 by an automated process through the openings in the flap 20, 80 using nozzles 130. The potting material flows into the battery pack 21 as a liquid, thereby filling the battery pack 21. The potting material then solidifies over time. As shown in fig. 23, the control module 27 is attached to the side wall 92; in addition, the control module 27 is also filled with the pouring material.

As soon as the battery 21 is filled with the filling material, the lower and upper shutters 20, 80 will be closed by an outer casing. The outer casing is a sheet metal component that is placed on the battery 21 before the potting material hardens. In the case of intumescent foam as the potting material, as it sets, the foam expands in contact with the outer shell. The potting material acts as an adhesive once cured, thereby attaching the outer casing to the battery 21. In one embodiment, the outer casing is attached to the battery 21 with external fasteners and potting material. In another embodiment, the outer casing is attached to the battery 21 with only the hardened/set/vulcanized potting material.

Figures 24-26 show schematic diagrams of the thermal control system 18. The thermal control system 18 includes a reservoir 150, a pump 25, a heat exchanger 23, a battery 21, a three-way control valve 180, and a switching module 181 connected to a control module 27. The reservoir 150 is a reservoir, configured to store coolant 151. Reservoir 150 is selectively in fluid communication with coolant loop 183 so that fluid within reservoir 150 can be supplied to coolant loop 183 to pressurize coolant loop 183. Similarly, coolant can be removed from coolant loop 183. fluid 183 to reduce the pressure in the coolant circuit 183, if necessary. Reservoir 150 may further be vented so that air pocket 152 may be positioned above coolant 151 when reservoir 150 is empty. If the level of coolant 151 in reservoir 150 falls below a threshold value, the user of battery 21 may inject coolant 151 into reservoir 150.

Three-way control valve 180 can be controlled to selectively turn reservoir 150 in fluid communication with coolant loop 183. In addition, three-way control valve 180 can be actuated to close coolant loop 183 so that coolant cannot flow through coolant loop 183. when the battery 21 is turned off.

Reservoir 150 is partially filled with coolant 151 and partially filled with air 152. Reservoir 150 may be hydraulically positioned vertically above coolant loop 183 so that coolant in coolant loop 183 is hydrostatically pressurized by pressure from coolant 151 in reservoir 150. Alternatively, air 152 within reservoir 150 may be pressurized such that a force is applied to coolant 151 within reservoir 150, which in turn acts on coolant in the coolant circuit.

On fig. 24 shows the thermal control system 18 in a non-operating state when the three-way control valve 180 is closed. In the non-operating state, the control valve 180 is closed and the pressure in the closed coolant circuit is maintained at the desired operating pressure.

Let's return to fig. 25: Thermal control system 18 can be pressurized by initiating a pressurization cycle in which coolant 151 from reservoir 150 is drawn into coolant circuit 183 to pressurize coolant in circuit 183. When the pressurization cycle is initiated, switch module 181 operates a three-way a control valve 180 to open two of the three valves so that a flow path is formed between the reservoir 150 and the pump 25. The third valve component is closed so that the coolant circuit 183 is blocked. Simultaneously, pump 25 is actuated to create a differential pressure across pump 25 so that liquid is drawn from reservoir 150 into coolant circuit 183. The drawing of liquid 151 from reservoir 150 into coolant loop 183 causes a pressure increase within coolant loop 183. Pressurizing the passage through the reservoirs makes it self-supporting, thereby eliminating any hydrodynamic pressure loss from the pump and greatly reducing pressure drop across the cooling system.

A pressure sensor (not shown) monitors the pressure in the coolant circuit 183 during the pressurization cycle, and when the desired pressure in the coolant circuit 183 is reached, the control valve 180 is actuated so that the path between reservoir 150 and the coolant circuit is closed. At the same time, the pump 25 may be stopped so that the thermal control system 18 switches to an inoperative state, or, alternatively, the pump 25 may be activated and the control valve 180 actuated to bring the thermal control system 18 into operation.

On fig. 26 shows the thermal control system 18 in operation. In operation, control valve 180 is actuated such that a flow path is formed through control valve 180 to allow coolant to circulate through coolant circuit 183. In operation, reservoir 150 is not in fluid communication with coolant circuit 183. Control module 27 can control the coolant pressure in the coolant circuit 183 to ensure that the coolant pressure is maintained at the desired operating pressure. If the pressure in the coolant loop 183 drops below a threshold value, a cycle to pressurize the coolant loop 183 to the target operating pressure may be started, as described above. The target operating pressure may be, for example, from 0.5 to 1.5 bar.

On fig. 27 shows an alternative thermal control system 18. As shown in fig. 27, thermal control system 18 includes a two-way control valve 182 located upstream of tank 150. Pump 210 is located between tank 150 and two-way control valve 182. Pump 210 is configured to pressurize tank 150 by forcing air from the atmosphere into tank 150 when the two-way control valve 182 is in the open position. The two-way control valve 182 may be closed when the desired pressure in the reservoir 150 is reached. This maintains the pressure in the reservoir 150.

Tank 150 shown in fig. 27 is in constant fluid communication with the coolant loop 183 so that the pressure in the coolant loop 183 can be maintained by the air pressure 152 inside the tank 150. The pressure inside the tank 150 can be controlled, and when the pressure inside the tank falls below the target operating value, the valve 182 and pump 210 may be operated to pressurize reservoir 150, and thus coolant loop 183, to a target operating pressure.

In the drawings and initially in Fig. 28-29, channel 230 is shown capable of contacting at least a portion of the surface area of heat source 30; conduit 230 extends along and interacts with at least a portion of the surface area of heat source 30 along all or part of the length of heat source 30 from a first post-inlet contact position 52 to at least one final post-exhaust contact position 54 between conduit 230 and heat source 30 The heat transfer fluid flows through the inner tube of the channel 230 so that heat can be transferred between the channel 230 and the heat source 30 through the heat transfer fluid along the cooperating surface areas of the channel 230 and the heat source 30. The channel 230 is adapted to provide variable heat transfer through the heat transfer fluid between contacting surface areas. channel 230 and heat source 30.

The channel 230 is adapted to provide variable heat transfer through the heat transfer fluid between the contact areas of the surface of the channel 230 and the heat source 30 along the length of the channel 230.

Provides the advantage that conduit 230 is adapted to create a variable heat transfer through the heat transfer fluid between contact areas of the conduit surface 230 and heat source 30 along the length of the conduit 230 to compensate for the heat transfer fluid temperature change resulting from continued heat transfer as the heat transfer fluid flows along the length of the conduit 230. This ensures uniform heat transfer between heat source 30 and conduit 230 through the heat transfer fluid along the length of conduit 230 as other parameters, such as fluid temperature, change. Heat source 30 is a battery 21 containing a plurality of cells 30. Conduit 230 is a flexible conduit, although conduit 230 is rigid in some embodiments. In these rigid embodiments, channel 230 is a metal or metal alloy channel.

Channel 230 is located close to the surface of heat source 30 so that heat can be transferred between channel 230 and heat source 30. Channel 230 is located close to the surface of elements 30 so that heat can be transferred between channel 230 and elements 30.

In one embodiment where conduit 230 is a 50/230 flexible conduit, potting material 231 (see Figure 30) is provided to act as a support for at least a portion of the 50/230 conduit. Provides the advantage that the flexible conduit 50/230 can closely conform to the shape of the surface of the heat source/cells 30 within the stack 21 by being reinforced with fill material 231 that prevents the flexible conduit 50/230 from overblowing and/or tearing.

Channel 230 is configured to transfer coolant from inlet 52 to outlet 54 to transfer thermal energy between the heat source/elements 30 and channel 230 at their interacting contact surfaces through the fluid coolant, wherein the thermal resistance of channel 230 at inlet 52 is higher than the thermal resistance of the channel at outlet 54. This is useful because changing the thermal resistance of channel 230 along the length of channel 230 contributes to uniform temperature distribution over the heat source/battery 21. In particular, the presence of a higher thermal resistance at the inlet to channel 230 prevents overcooling or heating of the heat source/elements 30 located near the inlet 52, where the temperature difference between the coolant and the heat source/elements 30 is maximum. The thermal resistance of channel 230 varies linearly or non-linearly along the length of channel 230; the thermal resistance of channel 230 is reduced as the temperature difference between the coolant and the heat source/elements 30 is also reduced, thereby facilitating uniform power dissipation along the length of channel 230.

In one embodiment, the wall thickness of the channel 230 may be greater at the inlet 52 than at the outlet 54, as shown in FIG. 29; in fig. 29 is a vertical section through the outlet and inlet duct 230 illustrating the change in the thickness of the duct wall. This is useful because increasing the wall thickness also increases the thermal resistance of the channel 230. As such, increasing the wall thickness of the inlet channel 230 also increases the thermal resistance of the channel 230.

In one embodiment, the wall thickness of the channel may vary linearly along the longitudinal length of the channel 230. In another embodiment, the wall thickness of the channel 230 may vary non-linearly along the longitudinal length of the channel 230. Changing the wall thickness of the channel 230 along the longitudinal length of the channel 230 has the effect of changing the thermal resistance of the channel 230 along its longitudinal length.

In one embodiment, the wall thickness can be varied so that a substantially constant power dissipation is achieved along the longitudinal length of the channel 230. This is useful because it helps to evenly distribute the temperature throughout the array of elements 30. This can be achieved by increasing the thermal resistance along the length channel 230.

On fig. 31 shows a schematic cross-section of a battery, generally designated 2000. Battery 2000 includes a conduit 2011 used to thermally control cells 2020. Conduit 2011 includes a flexible conduit material 2001 containing a matrix 2002 and a filler 2003. Fluid 2004 flows through the flexible conduit. e.g. air, water or water-glycol mixture. Heat is transferred between the elements 2020 and the coolant 204 through the channel material 2001.

The 2002 matrix is a flexible plastic or polymeric material, in this case LDPE, LLDPE, HDPE, polyester, silicone or rubber. Matrix 2002 is electrically insulating. The 2002 matrix has a thermal conductivity of less than 15 W-m ^-1 K ^-1 , ideally less than 10 W-m ^-1 K ^-1 , 5 W-m ^-1 K ^-1 and / or 1 W-m ^-1 K ^-1 .

Filler 2003 contains filler particles; they are dispersed throughout the matrix 2002. In preferred embodiments, the filler 2003 comprises NANOCYL (RTM) NC7000 series thin multi-walled carbon nanotubes, however, any suitable filler may be used, such as a carbon-based filler material such as carbon, carbon black, graphite, graphite plates, graphene, multi-walled carbon nanotubes or single-walled carbon nanotubes, or a ceramic filler such as aluminum oxide, silicon carbide, boron nitride, silicon nitrate, aluminum oxide, aluminum nitride or zinc oxide. The filler particles can be elongated and tubular, have a diameter of 1-10 nm and a length of 0.5-5 nm. Alternatively, the filler particles may be substantially spherical with an average diameter of 1 nm to 10 µm.

The thermal conductivity of the filler 2003 is greater than that of the matrix 2002. Ideally, the filler 2003 has a thermal conductivity of greater than 10 Wm ^-1 K ^-1 and/or greater than 100 Wm ^-1 K ^-1 . Channel material 2001 contains less than 25% by volume of filler 2003; ideally 5-18% by volume filler or 15% by volume filler 2003. Inclusion of a limited amount of filler 2003 in the matrix provides increased thermal conductivity while maintaining low electrical conductivity and favorable mechanical properties (i.e. suitable flexibility for the inflatable channel).

In this example, the channel material 2001 has a thermal conductivity greater than 0.33 W-m ^-1 K ^-1 at room temperature, ideally greater than 1 W-m ^-1 K ^-1 and/or 10 W-m ^-1 K ^{- 1} . This means that heat transfer through the 2011 channel material is better than that of a conventional polymer channel. The channel material 2001 is itself electrically insulating, as the electrical conductivity of the channel material 2001 is dominated by the electrical properties of the non-conductive matrix 2002. The electrically insulating nature of the channel/matrix material greatly reduces the risk of short circuits compared to a metal channel.

Channel 2011 is at least partially surrounded by potting material 2005 which reinforces channel 2011 where it does not contact the wall of element 2020. The inclusion of filler 2003 in matrix 2002 can change the mechanical properties of channel 2001, especially for high concentrations of filler 2003. Where this leads to any reduction in mechanical strength, a reinforcing material 5 can be used to counteract such effects. This embodiment may be used as an alternative or in combination with the variable wall thickness embodiment.

On fig. 32 and 33 show an additional support structure 1201 having an outer guide formation, an inner guide formation, and a guide channel 1205 therebetween. The support structure 1201 is used to prevent kinking, swelling and/or rupture of the flexible conduit where the conduit changes direction. The support structure 1201 is sized such that the elements located at the end of each row of the array have substantially the same area of thermal contact with the channel as the elements located in the center of the array. The support structure 1201 achieves this by shielding or thermally insulating a portion of the end members from thermal contact with the channel.

The outer guide formation of the support structure 1201 is formed by the combination of the outer leg 1208 and the inner surface 1211 of the outer battery case wall 1210 (see Fig. 33). The outer rack 1208 is located next to at least one element at the edge of the array of elements. The outer post 1208 is a block that has an element adjacent surface 1235 that is curved to fit the shape of the element side wall and an outer support surface 1209 that extends from the element adjacent surface 1235. The outer rack 1208 is integrally formed with the bottom flap 1237 of the battery case 1236.

The inflatable conduit is supported by both the outer support surface 1209 of the column 1208 and the inner surface 1211 of the battery wall 1210. The use of the battery wall 1210 as part of the outer guide formation eliminates the need for a larger support structure and thus reduces the width and eliminates dead space within the battery.

The inner guide formation of the support structure 1201 is formed by the combination of the inner leg 1206a and the mating portion 1206b. The inner rack 1206a is similar in design to the outer rack 1208. The inner rack 1206a is a unit that is integral with the bottom flap 1237 of the battery case 1238. The inner leg 1206a is located on the opposite side of the guide groove 1205 to the outer guide formation. The inner post 1206a has two curved edges 1239a, 1239b adjacent to the battery cells to abut two adjacent, spaced apart cells.

The inner post 1206a further has an inner support surface 1207 that extends between the surfaces 1239a, 1239b adjacent to the elements. The inner support surface 1207 of the inner post 1206a has a generally flat portion and a generally curved portion that extends from the generally flat portion to the side wall of the element. The inner support surface 1207 provides support to the channel, thereby preventing the channel from swelling and wrapping around the end member.

The mating portion 1206b is provided with a compressible pad bonded to the surface of the element. In particular, the pillow is an open cell polyvinyl chloride (PVC) tape. Alternatively, PVC or closed cell polyurethane foam or other suitable compressible material can be used. In use, the interface portion 1206b of the inner guide formation extends from the edge 1239a adjacent to the element, the first portion 1206a, and around the portion of the element to which it is attached. When the flexible conduit (not shown) is inflated, it is pressed against the inner post 1206a and the mating portion 1206b of the inner guide formation.

The mating portion 1206b is used to limit thermal contact between the channel and the peripheral element to which it is attached. Mating part 1206b wraps around the outer surface of the end element so that when the channel is located inside the guide path 1205, it does not contact the end element in the area of the mating part 1206b. The skilled reader will appreciate that the extent to which the mating portion 1206b extends around the end member depends on the required thermal contact between the channel and the members. The mating portion 1206b must extend around the end member sufficiently to ensure that the channel contacts the end member no more than any other member in the array.

The skilled artisan will appreciate that both the inner strut 1206a and the mating portion 1206b may be compressible and/or may be integrally connected to each other. The mating portion 1206b may be integral with the bottom flap 1237.

Turning now to Fig. 34-36, another embodiment of the support structure can be seen, indicated generally by reference numeral 1301. The support structure 1301 of this embodiment has an outer guide formation 1308, an inner guide formation 1306, and a guide channel 1305 therebetween. The support structure 1301 is used to prevent the flexible conduit from kinking, swelling, and/or tearing when the conduit changes direction. The support structure 1301 is sized so that the elements located at the end of each row of the array have substantially the same area of thermal contact with the channel as the elements located in the center of the array. The support structure 1301 achieves this by shielding or thermally insulating a portion of the end members from thermal contact with the channel.

The outer guide formation of the support structure 1301 is formed by the combination of the first outer leg 1308a, the second outer leg 1308b, and the inner surface 1311 of the outer battery case wall 1310 (see Fig. 36). The first and second vertical structures 1308a, 1308b are spaced apart and both are connected to the base 1312 of the support structure. The bottom flap 1337 of the battery case 1338 may include appropriate recesses to accommodate the base 1312 of the support structure at the edge of the array of cells, although in additional embodiments, the support structure 1301 may be integral with the bottom flap 1337.

The inflatable conduit is supported by the first outer strut 1308a, the second outer strut 1308b, and the inner surface 1311 of the battery wall 1310. The use of the battery wall 1310 as part of the outer guide formation eliminates the need for a larger support structure and therefore reduces the width and eliminates dead space within the battery.

The vertical structures 1308a, 1308b are curved and form the corners of the guide formation 1305. The gap between the vertical structures 1308a, 1308b can be used to draw an excess conduit through the support structure 1301 when the conduit is placed in the battery. The first outer strut 1308a and the second outer strut 1308b prevent the channel from expanding to wrap around the outside of the end member, causing increased contact of the end member with the channel.

The support structures can be made from any suitable rigid, semi-rigid, or compressible material that has sufficient stiffness to support the flexible conduit, such as metal, plastic, or rubber. In an important example, the support structures are made from a potting material used in a battery or have thermal expansion inhibiting properties similar to potting compound. For example, the support structures can be made by filling the potting material into a suitable shape, or by cutting the support structure from, for example, a block of pre-cured thermal insulation foam. Alternatively, the support(s) structure(s) may be integral with the walls of the battery, for example with either a top or bottom flap. In such examples, the support structures are extrusions of plastic shells rather than an insert inside the battery.

The qualified reader will appreciate that various changes and modifications may be made to the present invention without departing from the scope of the present application. The thermal management system described here can be used with any type of battery having one or more individual cells. For example, the present invention may be used in a battery within an auxiliary power unit (APU) for a long haul truck, a traction battery in a battery electric or hybrid vehicle, an energy storage system, or any other battery in a marine, aerospace, automotive , industrial and energy storage industries requiring thermal management.

The flexible conduit 50 may be in indirect contact with the side(s) surface(s) or any other(s) surface(s) of one or more members 30 via a mating region or mating material such as a housing shell surrounding the element( s) 30, or thermally conductive filler, paste or adhesive. In optional embodiments, the flexible conduit may at least partially contact the end face(s) of the element(s).

In the foregoing discussion of the invention, unless otherwise indicated, the disclosure of alternative values for the upper or lower limit of the allowed range of a parameter, in combination with an indication that one of the values is preferred over the other, should be construed as an implied statement that each intermediate parameter value, between the more preferred and the less preferred of the alternatives is itself preferred over the less preferred value, as well as each value between the less preferred value and an intermediate value.

The properties disclosed in the foregoing description or in the following drawings, expressed in their specific forms or in terms of the means for performing the disclosed function, or the method or process for achieving the disclosed result, as the case may be, may individually or in any combination of such characteristics be used to realize invention in its various forms.

Claims (50)

1. Rechargeable battery containing: one or more battery cells; a flexible conduit located close to the surface of at least one or one of the plurality of elements so that heat can be transferred between the conduit and at least one or one of the plurality of elements; and compounding means adapted to act as a support for at least a portion of the channel, wherein in use the shape of the channel partially conforms to the surface of one or more cells. 2. The battery according to claim 1, characterized in that it contains a plurality of channels. 3. The battery according to claim 1 or 2, characterized in that the single channel or each channel is in an expanded state. 4. Battery according to any one of paragraphs. 1-3, characterized in that the single channel or each channel contains one or more generally straight sections. 5. Battery according to any one of paragraphs. 1-4, characterized in that the single channel or each channel is a serpentine channel. 6. Battery according to any one of paragraphs. 1-5, characterized in that the battery contains an array of battery cells. 7. Battery according to any one of paragraphs. 1-6, characterized in that one or each element is a cylindrical element. 8. Battery according to any one of paragraphs. 1-7, characterized in that a single channel or each channel is located between and (or) next to one or more elements. 9. Battery according to any one of paragraphs. 1-8, characterized in that the single channel or each channel is in direct thermal contact with the side(s) surface(s) of one or more elements. 10. Battery according to any one of paragraphs. 1-9, characterized in that the single channel or each channel is in indirect thermal contact with the side(s) surface(s) of one or more elements through the mating area or mating material. 11. Battery according to any one of paragraphs. 1-10, characterized in that the single channel or each channel has an open configuration so that the cooling material can pass through the channel. 12. The battery of claim. 11, characterized in that the single channel or each channel is maintained in an open configuration by coolant under pressure within the single channel or each channel and / or by adhering to the filling means. 13. Battery according to any one of paragraphs. 1-12, characterized in that the pouring agent is a foam. 14. The battery according to claim 13, characterized in that the pouring agent is a heat-insulating foam. 15. The battery according to claim 13 or 14, characterized in that the pouring agent contains intumescent, foamed polyurethane and (or) polyurethane foam. 16. Battery according to any one of paragraphs. 1-12, characterized in that the pouring agent contains a thermosetting plastic, silicone rubber gel or epoxy resin. 17. Battery according to any one of paragraphs. 1-16, characterized in that the pouring means acts as a rigid support for at least a portion of at least one channel. 18. Battery according to any one of paragraphs. 1-17, characterized in that the pouring means locks the cell(s) and channel(s) in place within the battery. 19. Battery according to any one of paragraphs. 1-18, characterized in that the pouring means defines a cavity, inside which at least a part of at least one channel is located. 20. Battery according to any one of paragraphs. 1-19, characterized in that the pouring means is attached with glue to at least a part of one or more channels. 21. The battery according to any one of claims 1-20, characterized in that the single channel or each channel is formed from an inflatable plastic material. 22. The battery of claim. 20, characterized in that the inflatable plastic material is polyester, low density polyethylene (LDPE), linear low density polyethylene (LLDPE) or high density polyethylene (HDPE). 23. Battery according to any one of paragraphs. 1-22, characterized in that the channel is a single lumen channel. 24. Battery according to any one of paragraphs. 1-22, characterized in that the channel is a multi-lumen channel. 25. Battery according to any one of paragraphs. 1-24 comprising at least one reference means configured to support at least one channel. 26. The battery according to claim 25, characterized in that one or each support means is configured to support the channel at the point where the channel turns and/or reverses direction. 27. The battery according to claim 24 or 25, characterized in that one or each support means contains a guide groove. 28. Battery according to any one of paragraphs. 1-27, characterized in that it is functionally connected to the thermal control system. 29. A method of manufacturing a battery, including: providing one or more elements; placing the flexible inflatable conduit close to the surface of at least one or more elements so that heat can be transferred between the conduit and at least one or more elements; introducing liquid into the channel so that the shape of the channel partially matches the shape of the surface of one or more elements; and providing a pouring means adapted to act as a support for at least a portion of the channel. 30. The method of claim. 29, characterized in that it includes providing an array of elements. 31. The method according to claim 29 or 30, characterized in that it includes placing one or more cells in the battery case. 32. The method according to any one of paragraphs. 29-31, characterized in that it includes placing one or more additional channels close to the surface of one or more elements, so that heat can be transferred between the channel or each additional channel and at least one or more elements. 33. The method according to any one of paragraphs. 29-32, characterized in that it includes placing a single channel or each channel in position(s) next to the element(s) and (or) between the element(s). 34. The method according to any one of paragraphs. 29-33, characterized in that it includes placing a single channel or each channel along a winding path inside the battery. 35. The method according to any one of paragraphs. 29-34, characterized in that it includes placing a single channel or each channel close to the surface of at least one or more elements when this or each channel is in an uninflated state. 36. The method according to any one of paragraphs. 29-35, characterized in that it includes placing a portion of the channel within the support means to provide support for at least a portion of the channel. 37. The method according to any one of paragraphs. 29-36, characterized in that it includes placing a part of the channel inside the recess in the support means when the channel is in an uninflated state. 38. The method according to any one of paragraphs. 29-37, characterized in that at the stage of introducing liquid into one or each channel, the channel(s) expand(s) into an open configuration. 39. The method according to any one of paragraphs. 29-38, characterized in that it includes introducing a filler into the battery. 40. The method according to any one of paragraphs. 29-39, characterized in that it includes introducing the filling agent into the battery when the filling agent is in a viscous or liquid state. 41. The method according to any one of paragraphs. 29-40, characterized in that it includes the introduction of liquid into a single channel or each channel before introducing the filler into the battery. 42. The method according to any one of paragraphs. 29-41, characterized in that it includes pressurizing and (or) inflating a single channel or each channel before introducing the filler into the battery. 43. The method according to any one of paragraphs. 29-42, characterized in that it includes the introduction of an expandable filling means in the battery. 44. The method according to any one of paragraphs. 29-42, characterized in that it includes the introduction of foam into the battery. 45. The method according to any one of paragraphs. 29-44, characterized in that it includes the introduction of intumescent or polyurethane foam into the battery. 46. The method according to any one of paragraphs. 29-42, characterized in that it includes the introduction of a thermosetting plastic, silicone rubber gel or epoxy resin into the battery. 47. The method according to any one of paragraphs. 29-46, characterized in that it includes vulcanization or solidification of the filling means inside the battery. 48. The method according to any one of paragraphs. 29-47, characterized in that it includes vulcanization or solidification of the filling means inside the battery when the single channel or each channel is in an inflated state and (or) in an open configuration. 49. The method according to any one of paragraphs. 29-48, characterized in that it includes maintaining pressure within the channel until the pouring agent sets or hardens. 50. The method according to any one of paragraphs. 29-49, characterized in that it includes maintaining, by gluing to the filling means, one or each channel in an open configuration within the battery.

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