Cooling system directly in housing
View Patent ↗A rechargeable battery system, a battery pack, and methods of manufacturing the same are disclosed herein. The rechargeable battery system and/or battery pack can be for an electric vehicle. The rechargeable battery system and/or battery pack can include a plurality of battery cells arranged into one or more rows, a busbar, and a housing. The housing can include a plurality of receptacles that can engage with the plurality of battery cells to secure a relative position of the plurality of battery cells with respect to each other. The housing can define a cooling duct in thermal connection with the plurality of receptacles.
1. A battery pack for an electric vehicle, the battery pack comprising:
a plurality of battery cells arranged into one or more rows, wherein:
each of the plurality of battery cells comprises a first terminal and a second terminal;
a busbar configured to conduct electrical energy to and from at least some of the plurality of battery cells;
a housing comprising a plurality of receptacles configured to engage with the plurality of battery cells to secure a relative position of the plurality of battery cells with respect to each other, wherein the housing defines a cooling duct in thermal connection with the plurality of receptacles, wherein the housing comprises an entrance and an exit fluidly connected to the cooling duct of the housing; and
a heat exchanger fluidly connected to at least one of the entrance and the exit of the cooling duct,
wherein the heat exchanger and the cooling duct comprise a cooling fluid contained therein.
2. The battery pack of claim 1 , wherein the cooling fluid comprises a refrigerant.
3. The battery pack of claim 1 , wherein the housing comprises a top and a bottom.
4. The battery pack of claim 3 , wherein the receptacles are located in the top of the housing and comprise a plurality of cups.
5. The battery pack of claim 4 , wherein the cooling duct extends at least partially around the receptacles.
6. The battery pack of claim 5 , wherein the housing is electrically non-conductive.
7. The battery pack of claim 1 , wherein the cooling duct is configured to maintain desired cooling across the entire housing.
8. A method of manufacturing a battery pack for an electric vehicle, the method comprising:
arranging a plurality of battery cells into one or more rows, wherein each of the plurality of battery cells comprises a first terminal and a second terminal;
positioning a busbar configured to conduct electrical energy to and from at least some of the plurality of battery cells;
receiving the plurality of battery cells within a plurality of receptacles of a housing, wherein the receptacles are configured to engage with the plurality of battery cells to secure a relative position of the plurality of battery cells with respect to each other, wherein the housing defines a cooling duct in thermal connection with the plurality of receptacles, and wherein the housing comprises an entrance and an exit fluidly connected to the cooling duct of the housing;
fluidly connecting the entrance and exit of the cooling duct to a heat exchanger; and
filling the heat exchanger and the cooling duct with a cooling fluid.
9. The method of claim 8 , wherein the cooling fluid comprises a refrigerant.
10. The method of claim 8 , wherein the housing comprises a top and a bottom.
11. The method of claim 10 , wherein the receptacles are located in the top of the housing and comprise a plurality of cups.
12. The method of claim 8 , wherein the cooling duct extends at least partially around the receptacles.
13. The method of claim 12 , wherein the housing is electrically non-conductive.
14. The method of claim 13 , wherein the cooling duct is configured to maintain desired cooling across the entire housing.