Abstract: A cooling manifold and a method for manufacturing the cooling manifold are provided. The cooling manifold includes a housing that defines an interior region having a serpentine flow path therein. The housing has a first plurality of grooves extending from a first surface of the housing into the housing. The grooves do not fluidly communicate with the interior region. The first plurality of grooves receive a portion of a thermally conductive member therein to conduct heat energy from the thermally conductive member to the housing. The cooling manifold further includes a top cap configured to seal a first end of the housing and a bottom cap configured to seal a second end of the housing.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a battery cell and a cooling fin disposed adjacent to the battery cell. The cooling fin has a solid plate and first and second tab portions extending from first and second edges, respectively, of the solid plate. The first and second tab portions are bent perpendicular to a front surface of the battery cell. The cooling fin extracts heat energy from the battery cell thereto. The battery module further includes a first cooling manifold that contacts the first tab portion of the cooling fin. The first cooling manifold has at least one flow channel extending therethrough that receives a fluid therethrough. The first cooling manifold conducts heat energy from the cooling fin into the fluid flowing through the first cooling manifold to cool the battery cell.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a first battery cell and a cooling fin disposed adjacent to the first battery cell. The cooling fin has first and second headers, an extruded housing, and a flow diverter. The first and second headers are coupled to first and second ends, respectively, of the extruded housing. The extruded housing has a first plurality of flow channels and a second plurality of flow channels extending therethrough that fluidly communicate with the first and second headers. The flow diverter is disposed in the first header to induce a fluid to flow from the first header through the first plurality of flow channels in the extruded housing to the second header to extract heat energy from the first battery cell.

Abstract: A battery system is provided. The battery system includes a first battery cell assembly having first and second interconnect members. The first and second interconnect members have first and second blades, respectively. The battery system further includes an electrically non-conductive base member having first and second grooves. The battery system further includes first and second bus bar members disposed in the first and second grooves, respectively. The first bus bar member has a first aperture configured to removably receive the first blade therein. The second bus bar member has a second aperture configured to removably receive a second blade therein.

Abstract: A battery module and a related method are provided. The module includes battery cells having electrical terminals extending from battery portions. The module further includes an interconnect board having apertures for receiving the electrical terminals therethrough, and an elastomeric layer having apertures extending therethrough. The elastomeric layer is disposed proximate to the interconnect board such that the electrical terminals extend through the apertures of the interconnect board and further extend through the apertures of the elastomeric layer. The module further includes a potting compound disposed on the elastomeric layer such that the layer prevents the potting compound from contacting the battery portions.

Abstract: A battery pack and a liquid leak detection system are provided. The system includes first and second wire grids and an open-cell foam layer. The first and second wire grids are disposed on first and second sides, respectively, of the foam layer. The foam layer allows at least a portion of liquid contacting the foam layer to migrate from the first side to the second side. The system further includes an insulating mat disposed between the second wire grid and a tray. The system further includes a resistance measuring device that outputs a first signal indicative of a resistance level between the wire grids. The system further includes a microprocessor that compares an amplitude of the first signal to a threshold value, and outputs a second signal if the liquid is detected based on the comparison.

Abstract: A battery cell assembly, a heat exchanger, and a method for manufacturing the heat exchanger are provided. The heat exchanger includes a rectangular-shaped sheet having first and second rectangular-shaped sheet portions coupled together at a bent edge such that the sheet portions are disposed proximate to one another. Outer edges of the first and second rectangular-shaped sheet portions are coupled together such that an interior region is formed between the first and second rectangular-shaped sheet portions. The bent edge has first and second apertures extending therethrough. The heat exchanger further includes a first inlet port disposed on the bent edge over the first aperture, and a second outlet port disposed on the bent edge over the second aperture, such that fluid can flow through the first inlet port and into the interior region and then through the outlet port.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a battery cell and a cooling fin disposed adjacent to the battery cell. The cooling fin has a solid plate and first and second tab portions extending from first and second edges, respectively, of the solid plate. The first and second tab portions are bent perpendicular to a front surface of the battery cell. The cooling fin extracts heat energy from the battery cell thereto. The battery module further includes a first cooling manifold that contacts the first tab portion of the cooling fin. The first cooling manifold has at least one flow channel extending therethrough that receives a fluid therethrough. The first cooling manifold conducts heat energy from the cooling fin into the fluid flowing through the first cooling manifold to cool the battery cell.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a first battery cell and a cooling fin disposed adjacent to the first battery cell. The cooling fin has first and second headers, an extruded housing, and a flow diverter. The first and second headers are coupled to first and second ends, respectively, of the extruded housing. The extruded housing has a first plurality of flow channels and a second plurality of flow channels extending therethrough that fluidly communicate with the first and second headers. The flow diverter is disposed in the first header to induce a fluid to flow from the first header through the first plurality of flow channels in the extruded housing to the second header to extract heat energy from the first battery cell.

Abstract: A battery module and a method for cooling the battery module are provided. The battery module includes a housing having an electrically non-conductive oil disposed therein, and a battery cell disposed in the housing that contacts the electrically non-conductive oil. The battery module further includes first and second heat conductive fins disposed in the housing that contacts the electrically non-conductive oil. The first and second heat conductive fins extract heat energy from the electrically non-conductive oil. The battery module further includes first and second conduits extending through the first and second heat conductive fins, respectively. The first and second conduits receive first and second portions of a fluid, respectively, therethrough and conduct heat energy from the first and second heat conductive fins, respectively, into the fluid to cool the battery cell.

Abstract: A cooling system for a battery system and a method for cooling the battery system are provided. The cooling system includes a housing having first and second enclosed portions, and a first evaporator and a first evaporator fan disposed in the first enclosed portion that recirculates air in a first closed flow path loop within the first enclosed portion. The first evaporator extracts heat energy from the air in the first closed flow path loop to reduce a temperature level of a first battery module in the first enclosed portion. The cooling system further includes a condenser disposed in the second enclosed portion and fluidly coupled to the first evaporator, which receives heat energy in a refrigerant from the first evaporator and dissipates the heat energy. The cooling system further includes a compressor disposed in the second enclosed portion that recirculates the refrigerant through the first evaporator and the condenser.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a first battery cell, and a first cooling fin having a first panel portion and first and second rail portions that are disposed on first and second ends, respectively, of the first panel portion. The first battery cell is disposed adjacent to a first side of the first panel portion. The first and second rail portions have a thickness greater than the first panel portion. The first cooling fin conducts heat energy from the first battery cell into the first cooling fin to cool the first battery cell. The battery module further includes first and second conduits extending through the first and second rail portions, respectively, that receive a fluid that flows through the first and second conduits to conduct heat energy from the first cooling fin into the fluid.

Abstract: Battery systems, a battery module, and a method for cooling the battery module are provided. The battery module includes a housing having a non-conductive oil disposed therein. The battery module further includes a battery cell disposed in the housing. The battery module further includes a cooling manifold disposed in the housing that contacts the non-conductive oil. The cooling manifold is configured to receive a fluid therethrough and to conduct heat energy from the non-conductive oil into the fluid to cool the battery cell.

Abstract: Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a battery cell having a first side and a second side, and a first graphite sheet disposed on the first side of the battery cell that conducts heat energy from the battery cell into the first graphite sheet to cool the battery cell. The battery module further includes a first cooling manifold coupled to the first graphite sheet that conducts heat energy from the first graphite sheet into the first cooling manifold. The first cooling manifold is further configured to receive a fluid that flows therethrough to conduct heat energy from the first cooling manifold into the fluid.

Abstract: A cooling manifold and a method for manufacturing the cooling manifold are provided. The cooling manifold includes a housing that defines an interior region having a serpentine flow path therein. The housing has a first plurality of grooves extending from a first surface of the housing into the housing. The grooves do not fluidly communicate with the interior region. The first plurality of grooves receive a portion of a thermally conductive member therein to conduct heat energy from the thermally conductive member to the housing. The cooling manifold further includes a top cap configured to seal a first end of the housing and a bottom cap configured to seal a second end of the housing.

Abstract: A frame member for housing a battery cell, frame assembly and frame/battery cell assembly made therefrom, as well as respective methods of making the same, are disclosed. A frame member for housing a battery cell includes an integral frame having a peripheral wall, the peripheral wall having an attachment face and an opposed cooling face, and an attachment feature located on the attachment face and a complementary attachment feature located on the attachment face that is symmetrically opposed to the attachment feature about a plane of symmetry of the frame, the peripheral wall defining an opening that is configured to matingly receive a battery cell therein. A pair of frame members having a cooling member placed therebetween and attached to the respective attachment faces comprises a frame assembly. A frame/battery cell assembly includes a pair of frame assemblies having at least one battery cell placed therebetween.

Abstract: A battery cell assembly is provided. The battery cell assembly includes a battery cell and a heat exchanger disposed adjacent the battery cell configured to cool the battery cell. The heat exchanger has an outer housing. The outer housing defines an interior region and first and second flow guide members. The first and second flow guide members define a serpentine flow path in the interior region. The first and second flow guide members are tilted generally upwardly in the interior region. The serpentine flow path extends from an inlet aperture in the outer housing to another flow path in the outer housing. The another flow path extends from the serpentine flow path to an outlet aperture.

Abstract: A battery module having a cooling manifold is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers. The battery module further includes a first cooling manifold having a first inlet aperture extending therethrough and a first plurality of outlet apertures extending therethrough. The battery module further includes a first plurality of ported screws disposed through the first plurality of outlet apertures and configured to fluidly and physically couple the plurality of heat exchangers to the first cooling manifold.

Abstract: A battery module having a cooling manifold is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers. The battery module further includes the cooling manifold operably coupled to the plurality of battery cell assemblies. The cooling manifold has a manifold portion and a cover plate. The manifold portion has a peripheral wall, a rear wall coupled to the peripheral wall, and a flow diverter. The peripheral wall has a top portion with an inlet aperture extending therethrough. The rear wall has a plurality of outlet apertures extending therethrough. The cover plate is coupled to the peripheral wall opposite to the rear wall. The flow diverter extends from the rear wall and is disposed below the inlet aperture.

Abstract: A battery module is provided. The battery module includes a plurality of battery cell assemblies having a plurality of heat exchangers therein. The battery module includes a first rubber cooling manifold configured to route a fluid into the plurality of heat exchangers. The first rubber cooling manifold has a first tubular member, a first inlet port, a first plurality of outlet ports, and first and second end caps. The first end cap is coupled to a first end of the first tubular member. The second end cap is coupled to a second end of the first tubular member. The first inlet port is disposed on a top portion of the first tubular member for routing the fluid into the first tubular member. The first plurality of outlet ports is disposed collinearly and longitudinally along an outer surface of the first tubular member and spaced apart from one another. The first plurality of outlet ports extend outwardly from the outer surface of the first tubular member.