Systems and methods for battery thermal management utilizing a vapor chamber

1. A thermal management system, comprising:

a vapor chamber comprising a housing, a wicking material, and a working fluid;

a battery pack comprising a plurality of battery cells, each of the plurality of battery cells disposed at least partially within the vapor chamber; and

a capillary tube having an intake end at a first height within the vapor chamber and a return end at a second, lower height within the vapor chamber, wherein the working fluid condenses from vapor to liquid form within the capillary tube,

wherein each battery cell contacts a portion of the wicking material, and

wherein the working fluid changes phase within the vapor chamber in order to carry heat away from the battery cells.

2. The system of claim 1 , further comprising a heat pump coupled to the vapor chamber via a cold plate.

3. The system of claim 1 , wherein the wicking material comprises a post disposed at least partially between the battery cells.

4. The system of claim 3 , wherein the post is configured with an inner aperture to allow vapor passage therethrough.

5. The system of claim 3 , wherein the post extends from a first side of the vapor chamber to a second, opposite side of the vapor chamber.

6. The system of claim 3 , wherein the battery cells in the battery pack touch one another, and wherein the wicking material comprises a set of posts disposed in the spaces between the battery cells.

7. The system of claim 1 , wherein the wicking material is configured with at least one of a honeycomb pattern, a serial weave pattern, or a parallel weave pattern.

8. The system of claim 1 , wherein the wicking material contacts less than 90% of the surface area of a battery cell that is disposed within the vapor chamber.

9. The system of claim 1 , wherein the wicking material extends along less than 90% of the length of a battery cell that is disposed within the vapor chamber.

10. The system of claim 1 , wherein the wicking material extends partially along the length of a battery cell that is disposed within the vapor chamber, and wherein the wicking material tapers as it extends along the length of the battery cell.

11. The system of claim 1 , wherein a first set of battery cells in the plurality of battery cells is partially contained in the vapor chamber by a first percentage, and wherein a second set of battery cells in the plurality of battery cells is partially contained in the vapor chamber by a second percentage that is higher than the first percentage.

12. The system of claim 1 , wherein the thermal management system is operative to provide a level of thermal transfer to each battery cell that is at least 500 watts per meter-Kelvin (W/mK) and up to 2000 W/mK.

13. The system of claim 1 , wherein the wicking material is injection moldable, hydrophilic, and stretchable.

14. The system of claim 2 , wherein the thermal management system is operative without regard to the orientation of the thermal management system with respect to gravity.

15. The system of claim 1 , wherein the battery cells are cylindrical, wherein the wicking material comprises a first wicking portion and a second wicking portion, wherein the first wicking portion is configured to transport the working fluid in a direction generally perpendicular to the cylindrical axes of the battery cells, and wherein the second wicking portion is configured to facilitate vaporization of the working fluid.

16. The system of claim 1 , wherein evaporation of the working fluid from the wicking material provides a force to cause working fluid to exit the capillary tube at the return end.

17. The system of claim 2 , further comprising:

a condensation chamber coupled to the cold plate;

a capillary tube having an intake end at a first location within the vapor chamber and a return end at a second, different location within the vapor chamber, wherein the capillary tube passes at least partially through the condensation chamber.