Battery pack and a method of manufacturing a battery pack
A battery pack comprises one or more cells 30 , a flexible duct 50 positioned proximally to the surface of at least one of the one or more cells 30 such that heat can be exchanged between the duct 50 and at least one of the one or more cells 30 and a potting means which at least partially surrounds at least a part of the duct 50 . A method of manufacturing a battery pack comprises providing one or more cells 30 , positioning a flexible duct 50 proximally to the surface of at least one of the one or more cells 30 such that heat can be exchanged between the duct 0 and the at least one of the one or more cells 30 , inserting fluid into the duct 50 and at least partially surrounding at least a part of the duct 50 with a potting means. The potting means may be expandable foam.
1 . A battery pack comprising: one or more cells; a flexible and inflatable duct positioned proximally to a surface of at least one of the one or more cells such that heat can be exchanged between the duct and at least one of the one or more cells; and a potting material adapted to act as a support for at least a part of the duct wherein, in use, the duct partially conforms to the surface of the one or more cells by a heat transfer fluid flowing through the duct to pressurize the duct into an expanded state where no pre-formed radiused depressions are formed into the duct for conforming the duct in the expanded state to the one or more cells and wherein no portion of the duct comes into contact with another portion of the same duct further along a length of the duct or with a different duct, wherein the duct is free from internal obstructions such that in use a flow of the heat transfer fluid is not divided into separate paths in a same direction.
2 . A battery pack as claimed in claim 1 wherein the battery pack comprises a plurality of ducts.
3 . A battery pack as claimed in claim 1 wherein a coolant material is able to flow through the duct to pressurize the duct into the expanded state.
4 . A battery pack as claimed in claim 1 wherein the duct comprises one or more straight sections.
5 . A battery pack as claimed in claim 1 wherein the duct is a serpentine duct.
6 . A battery pack as claimed in claim 1 wherein the battery pack comprises an array of cylindrical cells.
7 . A battery pack as claimed in claim 1 wherein the duct is positioned between and/or adjacent to one or more cells in direct thermal contact with side surface(s) of the one or more cells.
8 . A battery pack as claimed in claim 1 wherein the duct is in indirect thermal contact with side surface(s) of the one or more cells via an interface region or an interface material.
9 . A battery pack as claimed in claim 1 wherein the duct has an open configuration such that a coolant material is able to flow through the duct and wherein the or each duct is maintained in the open configuration by pressurised coolant fluid within the or each duct and/or via adhesion to the potting material.
10 . A battery pack as claimed in claim 1 wherein the potting material comprises foam.
11 . A battery pack as claimed in claim 10 wherein the potting material comprises a thermally insulating foam.
12 . A battery pack as claimed in claim 1 wherein the potting material acts as a rigid support for at least apart of at least one duct.
13 . A battery pack as claimed in claim 1 wherein the potting material secures the one or more cells and the duct in position within the battery pack.
14 . A battery pack as claimed in claim 1 wherein the duct is formed from an inflatable plastics material, and the inflatable plastics material is polyester, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE) or high-density polyethylene (HDPE).
15 . A battery pack as claimed in claim 1 wherein the duct is a single-lumen duct or a multi-lumen duct.
16 . A battery pack as claimed in claim 1 comprising at least one support configured to provide support to at least one duct and wherein the or each support is configured to provide support to a duct at a point where the duct changes and/or reverses direction and wherein the or each support comprises a guide channel.
17 . A battery pack as claimed in claim 1 operably connected to a thermal management system.
18 . A method of manufacturing a battery pack, the method comprising: providing one or more cells; positioning a flexible and inflatable duct proximally to a surface of at least one of the one or more cells such that heat can be exchanged between the duct and the at least one of the one or more cells; inserting fluid into the duct to pressurize the duct into an expanded state such that the duct partially conforms to the surface of the one or more cells where no pre-formed radiused depressions are formed into the duct and wherein no portion of the duct comes into contact with another portion of the same duct further along a length of the duct or with a different duct; and providing a potting material adapted to act as a support for at least a part of the duct, wherein the duct is free from internal obstructions such that in use a flow of the fluid is not divided into separate paths in a same direction.
19 . A method as claimed in claim 18 wherein the method comprises inserting the potting material into the battery pack.
20 . A method as claimed in claim 18 wherein the method comprises inserting the potting material into the battery pack while the potting material is in a viscous or liquid state.
21 . A method as claimed in claim 18 wherein the method comprises curing or hardening the potting material within the battery pack.
22 . A method as claimed in claim 18 wherein the method comprises curing or hardening the potting material within the battery pack while the duct is in a inflated state and/or an open configuration.
23 . A method as claimed in claim 18 wherein the method comprises maintaining pressure within the duct until the potting material is set or hardened.
24 . A method as claimed in claim 18 wherein the method comprises maintaining, via adhesion to the potting material, the duct in an open configuration within the battery pack.
25 . A battery pack comprising: one or more cells; a flexible and inflatable duct positioned proximally to a surface of at least one of the one or more cells such that heat can be exchanged between the duct and at least one of the one or more cells; and a potting material adapted to act as a support for at least a part of the duct wherein, in use, the duct partially conforms to the surface of the one or more cells by a heat transfer fluid flowing through the duct to pressurize the duct into an expanded state where no pre-formed radiused depressions are formed into the duct for conforming the duct in the expanded state to the one or more cells and wherein no portion of the duct comes into contact with another portion of the same duct further along a length of the duct or with a different duct, wherein the duct comprises no partitions to divide a flow of the heat transfer fluid.