Abstract: Embodiments include an electric vehicle having a battery pack having a plurality of cylindrical battery cells. Each of the plurality of cylindrical battery cells includes an external housing, a jelly roll disposed within the external housing, an extended end cap affixed to one end of the external housing, the extended end cap including a central portion that extends a distance that is at least half of a height of the jelly roll into a central aperture of the jelly roll, and an isolation layer disposed between the jelly roll and the central portion and between the jelly roll and the external housing.

Abstract: A battery cell assembly includes a battery cell and a battery cell holder. The battery cell has a cell casing. The cell casing has an outer casing surface. The outer casing surface has a first plurality of grooves formed therein. The battery cell holder has a plurality of cell pockets. Each of the cell pockets has a wall. The wall has a wall surface. The wall surface has a second plurality of grooves that interact with the first plurality of grooves on the outer surface of the cell casing. The interaction of the first plurality of grooves on the cell casing with the second plurality of grooves on the wall of each of the plurality of cell pockets cooperates to prevent the battery cell from moving relative to the battery cell holder.

Abstract: A multi-cell rechargeable energy storage system (RESS) includes a plurality of battery cells arranged in rows and a single-piece cooling subsystem configured to remove thermal energy from the plurality of battery cells. The cooling subsystem includes a cell holder constructed from an impact-resistant material defining a plurality of pockets, wherein each pocket is configured to accept and retain one of the plurality of battery cells. The cooling subsystem also includes a coolant header disposed within the cell holder and having a plurality of ribbon coolant lines arranged in parallel and configured to circulate a coolant between individual battery cells. In a cross-sectional view, each ribbon coolant line is arranged inside the cell holder and over-molded and encased by a thermal interface material (TIM). Adjacent ribbon coolant lines embrace one row of the battery cells. A method of constructing the single-piece cooling subsystem is also included.

Abstract: Systems, methods and a cooling module are described. The cooling module is configured to directly cool the plurality of battery cell tabs. The cooling module includes a generally prismatic isolation sheet contacting the battery cell tabs along a common plane and a heat exchanger. The heat exchanger includes a metallic portion defining an open cavity and a lightweight portion joined to the metallic portion to define a unitary flow assembly. The metallic portion includes an outer planar surface engaging the second planar surface. The lightweight portion is formed from a thermally conductive plastic material and includes baffles integrally formed with and extending therefrom. The plurality of baffles engage an interior surface of the metallic portion to thereby define a serpentine path for the cooling fluid.

Abstract: Systems, methods and a cooling module are described. The cooling module is configured to directly cool the plurality of battery cell tabs. The cooling module includes a generally prismatic isolation sheet contacting the battery cell tabs along a common plane and a heat exchanger The heat exchanger includes a metallic portion defining an open cavity and a lightweight portion joined to the metallic portion to define a unitary flow assembly. The metallic portion includes an outer planar surface engaging the second planar surface. The lightweight portion is formed from a thermally conductive plastic material and includes baffles integrally formed with and extending therefrom. The plurality of baffles engage an interior surface of the metallic portion to thereby define a serpentine path for the cooling fluid.

Abstract: A battery module includes a plurality of battery cells and a battery module 4 housing configured to at least partially enclose the plurality of battery cells. The battery module housing includes at least one wall defining an outer periphery and an opposing inner periphery. A fluid interchange system includes one or more channels formed in and extending at least partially through the at least one wall, at least one inlet portion defined in and extending at least partially through the at least one wall, and at least one outlet portion defined in and extending at least partially through the at least one wall. A coolant is introduced to the fluid interchange system through the at least one inlet portion, circulated through the one or more channels and exits the fluid interchange system through the at least one outlet portion to cool the plurality of battery cells in the battery module housing.