Sealed battery module with cooling and heating

The system of claim, 9 wherein:

• the temperature sensor comprises a thermocouple operably connected to the controller;
• the first end plate defines an opening;
• and
• the system further includes:
• a nozzle coupled to the first cooling plate wall and fluidly connected to the coolant channel,
• a coolant connector extending from the nozzle and through the opening in the first end plate, the coolant connector being fluidly connected to the coolant channel via the nozzle,
• a first seal forming a substantially fluid-tight seal between the coolant connector and the first end plate, and
• a second seal forming a substantially fluid-tight seal between the coolant connector and the nozzle.

A battery module, comprising:

• a plurality of battery cells;
• a thermal interface material that is adhered to the plurality of batteries;
• and
• a housing that includes:
• a first end plate defining an opening,
• a second end plate disposed opposite the first end plate,
• a first side plate extending from the first end plate to the second end plate,
• a second side plate disposed opposite the first side plate and extending from the first end plate to the second end plate, wherein the plurality of battery cells is disposed between the first end plate and the second end plate, and between the first side plate and the second side plate;
• and
• a central wall extending from the first end plate to the second end plate;
• a heating pad comprising a first surface in contact with the thermal interface material, a second surface, and a central slot extending from the first surface to the second surface, wherein
• at least part of the central wall extends through the central slot, and
• the first surface disposed adjacent to the thermal interface material and includes a heating element that provides thermal energy to the plurality of battery cells via the thermal interface material;
• a cooling plate comprising:
• a first cooling plate wall forming a third surface of the cooling plate in contact with the second surface, and
• a second cooling plate wall separate from the first cooling plate wall and sealed to the first cooling plate wall, the second cooling plate wall forming a fourth surface of the cooling plate,
• the cooling plate configured to direct coolant through a coolant channel to remove thermal energy from the plurality of battery cells via the heating pad and the thermal interface material, the first cooling plate wall forming a first portion of the coolant channel and the second cooling plate wall forming a second portion of the coolant channel;
• a nozzle coupled to the first cooling plate wall and fluidly connected to the coolant channel,
• a coolant connector extending from the nozzle and through the opening in the first end plate, the coolant connector being fluidly connected to the coolant channel via the nozzle,
• a first seal forming a substantially fluid-tight seal between the coolant connector and the first end plate, and
• a second seal forming a substantially fluid-tight seal between the coolant connector and the nozzle.

A method, comprising:

• connecting a first side plate to a first end plate;
• connecting the first side plate to a second end plate disposed opposite the first end plate, the first side plate extending substantially perpendicular to the first end plate and the second end plate;
• connecting a second side plate to the first end plate and the second end plate, the second side plate extending substantially parallel to the first side plate, the first end plate, the second end plate, the first side plate, and the second side plate forming at least part of a battery module housing;
• connecting a center plate to the first end plate and the second end plate, the center plate extending substantially parallel to the first side plate and the second side plate;
• connecting a front plate to the first end plate, the front plate having a set of high voltage terminals configured to form an electrical connection with a plurality of battery cells disposed adjacent to the center plate;
• providing a cooling plate comprised of a first surface and a second surface opposite the first surface;
• adhering a heating pad to the first surface of the cooling plate, the heating pad having a third surface and a fourth surface in contact with the cooling plate opposite the third surface, at least part of the center plate extending through the heading pad from the third surface to the fourth surface;
• applying a thermal interface material to the third surface of the heating pad;
• connecting the cooling plate to the battery module housing such that the cooling plate is in thermal communication with the plurality of battery cells, the cooling plate securing the thermal interface material in contact with the plurality of battery cells and the heating pad in thermal communication with the plurality of battery cells;
• providing a temperature sensor disposed at a location within the battery module housing and proximate at least one battery cell of the plurality of battery cells;
• providing a controller operably connected to a component of the heating pad and the temperature sensor;
• and
• programming a controller to:
• receive a temperature indication determined by the temperature sensor,
• determine the temperature of the plurality of battery cells based at least in part on the temperature indication and using a stored thermal model corresponding to the plurality of battery cells, and
• control operation of the component of the heating pad or operation of a coolant pump fluidly connected to the cooling plate based at least in part on the determined temperature.