Abstract: A battery assembly includes a housing having a plurality of side walls that collectively define an interior zone. A plurality of battery cells is arranged in the interior zone. A support assembly connected to the housing supports the plurality of battery cells. The support assembly includes a support plate, an external structural plate, and a channeled cooling plate arranged between the support plate and the external structural plate, and a plurality of channeled cooling plate inflation ports that extend through the support plate towards the channeled cooling plate. The plurality of channeled cooling plate inflation ports introducing an amount of fluid into the support assembly to expand one or more portions of the channeled cooling plate.

Abstract: A coolant containment system for a battery pack includes a coolant retention container defining a containment space, an inlet connected to the coolant retention container, the inlet connected to an inlet line configured to receive a coolant, an outlet connected to the coolant retention container, the outlet connected to an outlet line, the outlet line configured return a coolant, a drain plug connected to the coolant retention container and in communication with the containment space. The inlet line and the outlet line are disposed entirely within the containment space and any coolant from a leak is retained within the containment space and exits the containment space to an environment outside the battery tray via the drain plug.

Abstract: A battery cell includes a battery can having a can bottom, a can top, a pair of can side walls, at least one seam, an electrode assembly disposed within the battery can, a thermally conductive junction disposed between the electrode assembly and an inside surface of the can bottom, and a pair of end cap plates. Each of the pair of end cap plates is disposed at opposing ends of the battery can. A top side of the thermally conductive junction is disposed adjacent to bottom edges of the electrode assembly, and a bottom side of the thermally conductive junction is fixedly attached to the inside surface of the can bottom, such that the thermally conductive junction electrically isolates the bottom edges of the electrode assembly from the battery can.

Abstract: A thermal management system comprising a plate including a first plate surface and a second plate surface opposite the first plate surface, one or more standoffs coupled to the plate, and one or more cooling channels coupled to the plate. The one or more cooling channels comprising a film layer comprising a first film surface facing and selectively coupled to the plate and a second film surface opposite the first film surface. The thermal management system furthering comprising a fluid arranged between the first film surface and the plate.

Abstract: A cooling beam having a first end and a second end spaced from the first end, and including a center plate extending between the first end and the second end, and a first surface and a second surface opposite the first surface, one or more cooling channels extending between the first end and the second end and coupled to the first surface and the second surface, and a coolant pathway arranged between the center plate and the one or more cooling channels, the coolant pathway configured to carry a fluid between one or more inlets and one or more outlets.

Abstract: A cooling beam having a first end and a second end spaced from the first end, comprising one or more outer plates extending between the first end and the second end, the one or more outer plates each having an upper end and a lower end that each extend between the first end and the second end of the cooling beam, and the one or more outer plates each having an inner surface and an outer surface spaced from the inner surface, one or more cooling channels extending between the first end and the second end and coupled to the inner surface of the one or more outer plates, and a coolant pathway arranged between the inner surface of the one or more outer plates and the one or more cooling channels, the coolant pathway configured to carry a fluid between one or more inlets and one or more outlets.

Abstract: A prismatic battery assembly includes a cell, a heat dissipating element, and a layer of anisotropic material. The cell includes an enclosure having a first end, a second end, a side wall extending between the first end and the second end, and a terminal disposed at the first end. The heat dissipating element extends along the second end. The layer of anisotropic material extends in a direction parallel to the side wall and has a first level of thermal conductivity in the direction parallel to the side wall and a second level of thermal conductivity in a direction transverse to the side wall. The first level of thermal conductivity is greater than the second level of thermal conductivity. Heat generated within the enclosure of the cell is dissipated along the layer of anisotropic material in the direction parallel to the side wall and into the heat dissipating element.

Abstract: A battery includes a prismatic cell can formed from steel. The prismatic cell can includes a first end, a second end spaced from the first end, a top surface, a bottom surface, a first side surface, and a second side surface that define a hollow can cavity. An anode current collector includes an anode foil tab. A cathode current collector includes a cathode foil tab. An anode terminal lead is secured to the anode foil tab. A cathode terminal lead is secured to the cathode foil tab. The anode current collector and the cathode current collector form an electrode stack arranged in the hollow can cavity with the anode terminal lead being connected to the bottom surface of the prismatic cell can forming a direct thermal pathway through the electrode stack to the bottom surface.

Abstract: Cold plates for liquid cooling systems, methods for the cold plates, and vehicles including the cold plates are provided. The methods include welding together a first substrate and a second substrate with weld lines, inflating portions of at least the second substrate between the weld lines to form a network of channels between the first substrate and the second substrate and thereby produce a cold plate, installing the cold plate to be in thermal contact with an apparatus that produces heat during operation thereof, wherein the apparatus includes a housing and the cold plate is welded to a portion of the housing or defines a portion of the housing, and coupling the cold plate to a liquid cooling system configured to supply a coolant to the network of channels to remove the heat from the apparatus.

Abstract: A battery pack is provided. The battery pack includes at least one battery cell including a cathode, an anode, and an electrolyte that transports charged ions between the anode and the cathode. The battery pack includes a thermal barrier within the battery pack for shielding the at least one battery cell from thermal exposure. The thermal barrier includes a mica substrate, a first coating layer disposed on a first side of the mica substrate, and a second coating layer disposed on a second side of the mica substrate. The second side is distal from the first side. The first coating layer and the second coating layer is formed of aluminum tri hydroxide (ATH).

Abstract: A battery cooling system, a method for cooling a battery cell, and vehicle provided with a battery cooling system are provided. A battery cooling system includes a rigid plate having a surface formed with channels; a flexible film contacting the surface and enclosing the channels; battery cells; and a coolant fluid located in the channels, wherein pressure from the coolant fluid pushes the flexible film into contact with the battery cells.

Abstract: A battery assembly includes a housing having a plurality of side walls that collectively define an interior zone. A plurality of battery cells is arranged in the interior zone. A support assembly connected to the housing supports the plurality of battery cells. The support assembly includes a support plate, an external structural plate, and a channeled cooling plate arranged between the support plate and the external structural plate, and a plurality of channeled cooling plate inflation ports that extend through the support plate towards the channeled cooling plate. The plurality of channeled cooling plate inflation ports introducing an amount of fluid into the support assembly to expand one or more portions of the channeled cooling plate.

Abstract: An immersion cooling system for a battery system includes a battery enclosure and C metal-encased, pouch-type battery cells including C metal cases, C pouch-type battery cells arranged in the C metal cases, respectively, where C is an integer greater than one, and C vents on the C metal cases, respectively. A vent gas manifold is in fluid communication with the C vents of the C metal cases and is configured to remove vent gas passing through the C vents of the C metal cases from the battery enclosure.

Abstract: A battery assembly includes a housing having a battery cell support surface and a plurality of side walls that collectively define an interior zone. A plurality of battery cells is arranged in the interior zone. A heat exchange member is mounted to the housing, the heat exchange member including a bottom plate. A cooling system is arranged in the heat exchange member. The cooling system includes an inflatable bladder arranged between the battery cell support surface and the bottom plate. The inflatable bladder is selectively inflated with a cooling fluid to be brought into contract with the battery cell support surface.

Abstract: Presented are thermal management systems using coolant flow distribution plates for immersion cooling of battery cells, methods for making/using such systems, and vehicles equipped with such systems for cooling the vehicles' battery packs. A battery assembly includes multiple battery cells arranged in adjacent, mutually parallel cell rows. The battery cells are stored inside a protective battery housing that includes inlet and outlet fluid ports for receiving and evacuating therethrough dielectric coolant fluid. A pair of (first and second) separator plates is located between each neighboring pair of cell rows. Each plate includes coolant channels that are arranged in mutually parallel channel bands. The separator plates are in face-to-face contact with each other such that each channel band of the first separator plate is aligned with a respective channel band of the second plate so the coolant channels cooperatively distribute coolant fluid onto and vertically upward between the battery cells.

Abstract: A method of making a cold plate includes stacking three aluminum sheets on top of each other while each of the three aluminum sheets is generally flat. An edge of the three aluminum sheets are secured together. A top one of the aluminum sheets is welded to a middle one of the aluminum sheets at a plurality of first locations and a bottom one of the aluminum sheets is welded to the middle one of the aluminum sheets at a plurality of second locations different than the plurality of first locations. A pressurized medium is supplied between the top one of the aluminum sheets and the bottom one of the aluminum sheets to separate the top one of the aluminum sheets from the bottom one of the aluminum sheets and deform the middle one of the aluminum sheets.

Abstract: A system, in accordance with a non-limiting example, includes a first member including a first electrical connector and a second member including a second electrical connector. The first member includes a rigid base and a resilient connector support coupled to the rigid base. The first electrical connector is being mounted to the resilient connector support.

Abstract: A coolant containment system for a battery pack includes a coolant retention container defining a containment space, an inlet connected to the coolant retention container, the inlet connected to an inlet line configured to receive a coolant, an outlet connected to the coolant retention container, the outlet connected to an outlet line, the outlet line configured return a coolant, a drain plug connected to the coolant retention container and in communication with the containment space. The inlet line and the outlet line are disposed entirely within the containment space and any coolant from a leak is retained within the containment space and exits the containment space to an environment outside the battery tray via the drain plug.

Abstract: An immersion cooling system for a battery system includes a battery enclosure and G battery cell groups arranged in the battery enclosure. Each of the G battery cell groups include C battery cells, where G and C are integers greater than one. A plurality of dividers are arranged between each of the G battery cell groups. A gas manifold removes vent gases from each of the G battery cell groups.

Abstract: Presented are thermal management systems using coolant flow distribution plates for immersion cooling of battery cells, methods for making/using such systems, and vehicles equipped with such systems for cooling the vehicles' battery packs. A battery assembly includes multiple battery cells arranged in adjacent, mutually parallel cell rows. The battery cells are stored inside a protective battery housing that includes inlet and outlet fluid ports for receiving and evacuating therethrough dielectric coolant fluid. A pair of (first and second) separator plates is located between each neighboring pair of cell rows. Each plate includes coolant channels that are arranged in mutually parallel channel bands. The separator plates are in face-to-face contact with each other such that each channel band of the first separator plate is aligned with a respective channel band of the second plate so the coolant channels cooperatively distribute coolant fluid onto and vertically upward between the battery cells.