Battery mounting and cooling system

Abstract

A battery system is provided in which the batteries are mounted between a pair of substrates, the system further including at least one cooling tube mounted next to the batteries, the cooling tube used to withdraw heat from the batteries via a circulating liquid coolant.

1 . A battery system, comprising:
 a plurality of batteries, wherein each of said plurality of batteries is comprised of a first end portion and a second end portion;   a first substrate, wherein said first substrate is rigid and comprised of a first electrically non-conductive material, said first substrate further comprising:
 a first plurality of battery mounting wells corresponding to said plurality of batteries; and 
 a first plurality of through-holes corresponding to said first plurality of battery mounting wells, wherein said first plurality of through-holes pass completely through said first substrate, and wherein said first end portion of each of said plurality of batteries is positioned within a corresponding battery mounting well of said first plurality of battery mounting wells; 
   a second substrate, wherein said second substrate is rigid and comprised of a second electrically non-conductive material, said second substrate further comprising:
 a second plurality of battery mounting wells corresponding to said plurality of batteries; and 
 a second plurality of through-holes corresponding to said second plurality of battery mounting wells, wherein said second plurality of through-holes pass completely through said second substrate, and wherein said second end portion of each of said plurality of batteries is positioned within a corresponding battery mounting well of said second plurality of battery mounting wells; 
   a first plurality of conductors coupling together a first plurality of battery terminals corresponding to said plurality of batteries, wherein said first plurality of conductors pass through said first plurality of through-holes;   a second plurality of conductors coupling together a second plurality of battery terminals corresponding to said plurality of batteries, wherein said second plurality of conductors pass through said second plurality of through-holes; and   at least one thermally conductive cooling tube containing a liquid coolant, said at least one thermally conductive cooling tube positioned to be proximate a side portion of each of said plurality of batteries, and wherein an outer surface of said at least one thermally conductive cooling tube is comprised of an electrically insulating material.   
     
     
         2 . The battery system of  claim 1 , wherein said at least one thermally conductive cooling tube is comprised of aluminum and wherein said outer surface of said at least one thermally conductive cooling tube is comprised of anodized aluminum. 
     
     
         3 . The battery system of  claim 1 , wherein said liquid coolant is selected from the group of liquid coolants consisting of water and anti-freeze based liquid coolants. 
     
     
         4 . The battery system of  claim 1 , further comprising a thermally conductive material interposed between said plurality of batteries and said at least one thermally conductive cooling tube, wherein said thermally conductive material is electrically non-conductive. 
     
     
         5 . The battery system of  claim 4 , wherein said thermally conductive material is comprised of a potting compound. 
     
     
         6 . The battery system of  claim 1 , wherein said at least one thermally conductive cooling tube passes each of said plurality of batteries at least twice and is proximate to said side portion of each of said plurality of batteries at at least two locations. 
     
     
         7 . The battery system of  claim 1 , wherein said at least one thermally conductive cooling tube is comprised of at least two cooling tubes configured as a single cooling structure, wherein said liquid coolant flows in one direction through a first tube of said at least two cooling tubes and in a second direction through a second tube of said at least two cooling tubes, wherein said first and second directions are opposite of each other. 
     
     
         8 . The battery system of  claim 1 , further comprising a pump coupled to said at least one thermally conductive cooling tube, wherein said pump circulates said liquid coolant through said at least one thermally conductive cooling tube and through a radiator. 
     
     
         9 . The battery system of  claim 1 , further comprising a pump coupled to said at least one thermally conductive cooling tube, wherein said pump circulates said liquid coolant through said at least one thermally conductive cooling tube and through a heat exchanger. 
     
     
         10 . The battery system of  claim 1 , wherein each of said first plurality of through-holes is centered within each corresponding battery mounting well of said first plurality of battery mounting wells, and wherein each of said second plurality of through-holes is centered within each corresponding battery mounting well of said second plurality of battery mounting wells. 
     
     
         11 . The battery system of  claim 1 , wherein each of said first plurality of battery mounting wells is comprised of a first substrate recess fabricated in said first substrate, said first substrate recess having a diameter that is substantially the same as a diameter corresponding to said first portion of said corresponding battery of said plurality of batteries, and wherein each of said second plurality of battery mounting wells is comprised of a second substrate recess fabricated in said second substrate, said second substrate recess having a diameter that is substantially the same as a diameter corresponding to said second portion of said corresponding battery of said plurality of batteries. 
     
     
         12 . The battery system of  claim 1 , wherein each of said first plurality of battery mounting wells is comprised of a first substrate recess fabricated in said first substrate, wherein said first substrate recess includes a plurality of teeth that deform upon insertion of said first portion of said corresponding battery, and wherein each of said second plurality of battery mounting wells is comprised of a second substrate recess fabricated in said second substrate, wherein said second substrate recess includes a plurality of teeth that deform upon insertion of said second portion of said corresponding battery. 
     
     
         13 . The battery system of  claim 1 , wherein each of said first plurality of battery mounting wells is comprised of a first substrate recess fabricated in said first substrate, wherein said first substrate recess includes a plurality of deformable fins that deform upon insertion of said first portion of said corresponding battery, and wherein each of said second plurality of battery mounting wells is comprised of a second substrate recess fabricated in said second substrate, wherein said second substrate recess includes a plurality of deformable fins that deform upon insertion of said second portion of said corresponding battery. 
     
     
         14 . The battery system of  claim 1 , wherein said first electrically non-conductive material and said second electrically non-conductive material are comprised of the same material. 
     
     
         15 . The battery system of  claim 1 , wherein said first and second electrically non-conductive materials are selected from the group of materials consisting of fiberglass and plastic. 
     
     
         16 . The battery system of  claim 1 , wherein said plurality of batteries utilize an 18650 form factor.