Battery module for vehicle energy-storage systems
Provided are battery modules. Each module may comprise an enclosure having a base, the base having a plurality of first holes disposed therein, the enclosure including a coolant input port, a coolant output port; the enclosure having a coolant sub-system for circulating coolant being directed into the enclosure through the coolant input port and the plurality of first holes and out of the enclosure through the coolant output port; a center divider affixed to the enclosure; a module cover coupled to the enclosure at an opposite end of the module from the center divider; a retainer disposed within the enclosure and configured to support a plurality of cells; a current carrier disposed between the module cover and the retainer; and the plurality of cells disposed between the current carrier and the center divider, the cells being coupled to and supported by the retainer.
1. An energy-storage system for a vehicle comprising:
a plurality of modules fluidly coupled in series along a linear liquid coolant flow path, each module including:
an enclosure including a base, the base having a plurality of holes disposed therein, the enclosure including a coolant input port disposed along the linear liquid coolant flow path, a coolant output port disposed along the linear liquid coolant flow path, a channel connected to a channel of an adjacent one of the plurality of modules to define a contiguous linear portion of the linear liquid coolant flow path, and a power connector; the enclosure having a coolant sub-system for circulating coolant being directed into the enclosure through the coolant input port and the plurality of holes and out of the enclosure through the coolant output port;
a blast plate coupled to the base of the enclosure;
a module cover disposed at an opposite end of the module from the blast plate;
a retainer disposed within the enclosure and configured to support a plurality of cylindrical cells;
a current carrier disposed between the module cover and the retainer and electrically coupled to the power connector; and
the plurality of cylindrical cells disposed in the enclosure and secured by the retainer and the base, the plurality of cylindrical cells having cylinder axes parallel to the contiguous linear portion of the linear liquid coolant flow path, electrical connections being formed between the plurality of cells and the current carrier.
2. The energy storage system of claim 1 , wherein the plurality of holes each have a diameter in a range from 0.1 mm-5 mm.
3. The energy storage system of claim 2 , wherein the plurality of holes are disposed on the base such that each hole of the plurality of holes receives substantially the same inlet pressure and approximately the same volume flow is maintained through each hole.
4. The energy storage system of claim 3 , wherein the substantially same inlet pressure is in a range of 0.05 psi-5 psi and the approximately same volume flow is 0.05 L/min-5 L/min.
5. The energy storage system of claim 1 , wherein the module cover, the enclosure, and the blast plate are each comprised of at least one: of polycarbonate, polypropylene, acrylic, nylon, and acrylonitrile butadiene styrene (ABS), and the module cover and the blast plate are each affixed to the enclosure, forming a hermetic seal.
6. The energy-storage system of claim 1 , wherein the module cover and blast plate comprise laser-transmissive polycarbonate, the enclosure comprises laser-absorptive polycarbonate, and the module cover and the blast plate are each affixed to the enclosure using at least laser welding, forming a hermetic seal.
7. The energy-storage system of claim 1 further comprising:
a tray having the plurality of modules disposed therein, the tray including: a positive bus bar;
a negative bus bar, the positive and negative bus bars being separately electrically coupled to the power connectors associated with the plurality of modules; and
a plurality of lateral supports; and
a coolant system for circulating coolant being pumped into the tray such that each of the modules is at approximately the same predetermined temperature,
wherein the enclosure further includes a first tab disposed at a first end of the enclosure and a second tab disposed at a second end of the enclosure, the first end being distal from the second end, and the first tab and the second tab being mechanically coupled to a respective lateral support of the plurality of lateral supports.
8. An energy-storage module for a vehicle comprising:
a housing enclosing a first group of cylindrical battery cells and a second group of cylindrical battery cells, the housing including a coolant inlet port configured to receive liquid coolant and a coolant outlet port configured to release liquid coolant, the coolant inlet port and the coolant outlet port disposed along a linear liquid coolant flow path, the housing further including a channel configured to be connected to a channel of an adjacent energy-storage module to define a contiguous linear portion of the linear liquid coolant flow path parallel to cylinder axes of the first group of cylindrical battery cells and the second group of cylindrical battery cells; and
a cooling system formed within the housing between the coolant inlet port and the coolant outlet port, the cooling system is configured to separate the liquid coolant into a first coolant flow directed to the first group of cylindrical battery cells and a second coolant flow directed to the second group of cylindrical battery cells,
wherein the first coolant flow flows over the first group of cylindrical battery cells in a first direction and the second coolant flow flows over the second group of cylindrical battery cells in a second direction, and
wherein the first direction and the second direction are opposite to each other.