Methods and systems for battery pack thermal management
Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module, A thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries,
1. A thermal control module for controlling temperature of batteries in a battery pack, the thermal control module comprising:
a thermal plate, comprising:
a first portion, comprising a first side;
a second portion, comprising a second side, offset relative to the first side of the first portion and at least partially defining an interior of the thermal control module together with the first portion, wherein the first portion is attached to the second portion;
thermal fluid ports, configured to connect to thermal fluid lines and flow a thermal fluid in and out of the interior of the thermal control module; and
a first battery engagement component, monolithic with the first portion of the thermal plate and comprising first extension channels,
wherein each of the first extension channels comprises first battery receiving openings and first bridging portions such that each of the first bridging portions is disposed between and joins two adjacent ones of the first battery receiving openings, and
wherein the first battery engagement component is configured to thermally couple a first set of the batteries to the thermal plate, to electrically insulate the first set of the batteries from the thermal plate, and to fluidically isolate the first set of the batteries from the thermal fluid.
2. The thermal control module of claim 1 , wherein:
the thermal plate comprises a plurality of diffusers disposed within the interior and supported by at least one of the first side or the second side,
the plurality of diffusers is configured to redirect the thermal fluid through the interior.
3. The thermal control module of claim 2 , wherein the plurality of diffusers is arranged into rows with varying angles of diffusing surfaces.
4. The thermal control module of claim 3 , wherein the angles of the diffusing surfaces differ for two adjacent ones of the rows of the plurality of diffusers.
5. The thermal control module of claim 1 , wherein:
the thermal plate comprises a divider, extending between the first side and the second side separating at least a portion of the interior into a first part and a second part,
one of the thermal fluid ports is in fluidic communication with the first part of the interior, and
another one of the thermal fluid ports is in fluidic communication with the second part of the interior.
6. The thermal control module of claim 1 , wherein both of the thermal fluid ports are positioned on a same end of the thermal plate.
7. The thermal control module of claim 1 , wherein:
the first battery engagement component comprises a thermal extension and a sleeve,
the thermal extension is formed from a metal,
the sleeve is formed from a thermally-conductive polymer or a thermally-conductive coating, and
the sleeve forms at least a portion of each of the first battery receiving openings.
8. The thermal control module of claim 1 , wherein the first extension channels extend to and is at least partially formed by the first portion.
9. The thermal control module of claim 1 , wherein a width of each of the first extension channels is variable.
10. The thermal control module of claim 9 , wherein a diameter of each of the first battery receiving openings corresponds to a highest value of to a width of a corresponding one of the first extension channels.
11. The thermal control module of claim 7 , wherein:
the sleeve comprises a plurality of sleeve cups, separated from each other; and
the plurality of sleeve cups forms a portion of each of the first extension channels and defines each of the first battery receiving openings.
12. The thermal control module of claim 1 , further comprising a second battery engagement component, monolithic with the second portion of the thermal plate and comprising second extension channels,
wherein each of the second extension channels comprises second battery receiving openings and second bridging portions such that each of the second bridging portions is disposed between and joins two adjacent ones of the second battery receiving openings, and
wherein each of the second battery receiving openings is configured to receive one of the batteries, such that the second battery engagement component is configured to thermally couple a second set of the batteries to the thermal plate, to electrically insulate the second set of the batteries from the thermal plate, and to fluidically isolate the second set of the batteries from the thermal fluid.
13. The thermal control module of claim 12 , wherein each of the first battery engagement component and the second battery engagement component comprises an insulating coating, electrically insulating the batteries from the thermal plate.
14. The thermal control module of claim 1 , wherein the thermal fluid ports are both parts of the first portion of the thermal plate.
15. The thermal control module of claim 2 , wherein:
the plurality of diffusers comprises a first set and a second set;
the first set of the plurality of diffusers is monolithic with the first portion of the thermal plate; and
the second set of the plurality of diffusers is monolithic with the second portion of the thermal plate.
16. The thermal control module of claim 15 , wherein each of the first set of the plurality of diffusers is aligned with a corresponding one of the second set of the plurality of diffusers.
17. The thermal control module of claim 11 , wherein each of the plurality of sleeve cups comprises side cutouts, aligned with corresponding ones of the first bridging portions of the first extension channels.
18. The thermal control module of claim 7 , wherein the thermally-conductive polymer of the sleeve comprises ceramic filer.
19. The thermal control module of claim 7 , wherein the sleeve is continuous, at least within each of the first extension channels.
20. The thermal control module of claim 1 , wherein the first bridging portions are open and exposed.