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 - 16 . (canceled) 
     
     
         17 . An energy storage system comprising:
 a plurality of cells each having a cylinder shape, wherein a cell axis extends between first and second ends of each cell;   first and second substrates holding the cells in a grid formation with rows and columns; and   a tube configured to provide circulation of liquid in directions generally transverse to the cell axes, the tube having sections each running along an entire length of one of the rows or columns from one side of the grid formation to an opposite side of the grid formation, adjacent ones of the sections connected to each other by turnaround sections of the tube where the tube turns to reverse direction.   
     
     
         18 . The energy storage system of  claim 17 , wherein at least one conductive element per cell is glued to the first or second substrates. 
     
     
         19 . The energy storage system of  claim 17 , further comprising a thermally conductive insulating layer interposed between a surface of the tube and contact surfaces of the plurality of cells. 
     
     
         20 . The energy storage system of  claim 17 , configured so that the plurality of cells are held in place within the energy storage system only by the tube and the first and second substrates. 
     
     
         21 . The energy storage system of  claim 17 , wherein the liquid comprises a liquid refrigerant, the energy storage system further comprising a compressor that compresses the refrigerant, wherein the compressor provides the compressed refrigerant to a condenser in the energy storage system and is further configured to provide cooling of air for a passenger compartment. 
     
     
         22 . The energy storage system of  claim 17 , wherein the tube comprises an aluminum extrusion having multiple tubes defined therein. 
     
     
         23 . The energy storage system of  claim 17 , wherein at least one of the first and second substrates has a plurality of mounts configured to receive the first or second ends of the cells, a center of each mount having a hole through the substrate. 
     
     
         24 . The energy storage system of  claim 23 , wherein each hole through the substrate has one or more teeth, petals or fins. 
     
     
         25 . The energy storage system of  claim 23 , further comprising a plate positioned by an outside of the first or second substrate, the plate electrically connected to cell terminals through the holes in the first or second substrate. 
     
     
         26 . The energy storage system of  claim 17 , wherein the first and second substrates are identical. 
     
     
         27 . The energy storage system of  claim 17 , wherein adjacent sets of cells are alternately positioned. 
     
     
         28 . The energy storage system of  claim 17 , further comprising a plurality of perimeter walls enclosing the cells, the perimeter walls mounted between the first and second substrates. 
     
     
         29 . The energy storage system of  claim 28 , wherein the perimeter walls are attached to at least one of the first and second substrates using a fastener molded into the first or second substrate. 
     
     
         30 . The energy storage system of  claim 17 , wherein the sections are straight and parallel to each other, and wherein each of the turnaround sections forms a U-turn. 
     
     
         31 . An energy storage system comprising:
 a plurality of cells each having a cylinder shape, wherein a cell axis extends between first and second ends of each cell;   first and second substrates holding the cells in a grid formation with rows and columns; and   means for providing circulation of liquid in directions generally transverse to the cell axes, the means having sections each running along an entire length of one of the rows or columns from one side of the grid formation to an opposite side of the grid formation, adjacent ones of the sections connected to each other by turnaround sections of the means where the means turns to reverse direction.   
     
     
         32 . A method of manufacturing an energy storage system, the method comprising:
 assembling a plurality of cells with regard to at least a first substrate, each cell having a cylinder shape, wherein a cell axis extends between first and second ends of each cell, the first substrate holding the cells in a grid formation with rows and columns;   placing a tube among the cells, the tube having sections each running along an entire length of one of the rows or columns from one side of the grid formation to an opposite side of the grid formation, adjacent ones of the sections connected to each other by turnaround sections of the tube where the tube turns to reverse direction; and   assembling a second substrate onto the assembly of the first substrate, the cells and the tube so that the cells are held in place within the energy storage system only by the tube and the first and second substrates.   
     
     
         33 . The method of  claim 32 , wherein the tube is initially substantially straight, the method further comprising bending the tube into shape to form the turnaround sections such that the sections are essentially parallel to each other. 
     
     
         34 . The method of  claim 32 , further comprising providing electrical insulation between the tube and contact surfaces of the cells.