Interconnection-less liquid fin design for battery cooling module

1. A battery module comprising:

a plurality of cooling fins, each of said plurality of cooling fins having three panels formed from a single fin which is bent to create an inlet section, a center section, and an outlet section, the inlet and outlet sections extending from opposite ends of the center section at an angle away from a plane defined by the center section, the cooling fins having at least one cooling channel extending from an inlet of the inlet section through the center section to an outlet of the outlet section; and

a plurality of battery cells positioned in the center section between the plurality of cooling fins.

2. The battery module of claim 1 wherein the inlet and outlet sections extend in opposite directions from the plane.

3. The battery module of claim 1 wherein the angle is about 90°.

4. The battery module of claim 1 wherein there are a plurality of cooling channels in each cooling fin.

5. The battery module of claim 1 further comprising an expansion unit positioned between the battery cells.

6. The battery module of claim 5 wherein the expansion unit is a layer of foam.

7. The battery module of claim 1 wherein the inlets and outlets of the plurality of cooling fins are aligned.

8. The battery module of claim 1 wherein the cooling fin is about 1 mm thick.

9. The battery module of claim 1 wherein a bending radius of the cooling fin is about 2 mm.

10. A battery module comprising:

a plurality of cooling fins wherein each cooling fin comprises three panels formed from a single fin which is bent to create an inlet section, a center section, and an outlet section, the inlet and outlet sections extending from opposite ends of the center section at an angle of about 90° away from a plane defined by the center section, the cooling fins having a plurality of cooling channels extending from an inlet of the inlet section through the center section to an outlet of the outlet section wherein the inlets and outlets of the plurality of cooling fins are aligned; and

a plurality of battery cells positioned in the center section between the plurality of cooling fins.

11. The battery module of claim 10 further comprising an expansion unit positioned between the battery cells.

12. A method of cooling a battery module comprising:

providing a battery module comprising:

a plurality of cooling fins having three panels formed from a single fin which is bent to create an inlet section, a center section, and an outlet section, the inlet and outlet sections extending from opposite ends of the center section at an angle away from a plane defined by the center section to form a straight “z” shape, the cooling fins having at least one cooling channel extending from an inlet of the inlet section through the center section to an outlet of the outlet section; and

a plurality of battery cells positioned in the center section between the plurality of cooling fins;

connecting the at least one cooling channel to an inlet manifold at an inlet end and to an outlet manifold at an outlet end; and

circulating cooling fluid through the at least one cooling channel.

13. The method of claim 12 wherein the inlet and outlet sections extend in opposite directions from the plane.

14. The method of claim 12 wherein the angle is about 90°.

15. The method of claim 12 wherein there are a plurality of cooling channels.

16. The method of claim 12 further comprising an expansion unit positioned between the battery cells.

17. The method of claim 16 wherein the expansion unit is a layer of foam.

18. The method of claim 12 wherein the inlet and outlet ends of the plurality of the cooling fins are aligned.

19. The method of claim 12 wherein the cooling fin is about 1 mm thick.

20. The method of claim 12 wherein a bending radius of the cooling fin is about 2 mm.