Directed cooling thermal management system and method of operation

A directed cooling system, comprising:

• a pack housing defining an enclosed volume having a first side and a second side disposed opposite the first side;
• a proximal battery module disposed within the enclosed volume adjacent the first side;
• a distal battery module disposed within the enclosed volume adjacent the proximal battery module;
• a first header disposed on the first side of the enclosed volume and including a first aerodynamic structure;
• a second header disposed on the second side of the enclosed volume and including a second aerodynamic structure;
• a plurality of channels disposed between the first side and the second side, a first channel disposed adjacent the proximal battery module, a second channel disposed between the proximal and distal battery modules, and a third channel disposed adjacent the distal battery module;
• and
• an air cycle system passing an airflow into the enclosed volume through the first header, through the first, second, and third channels and over the proximal and distal battery modules, and out of the enclosed volume through the second header.

A method of operating a cooling system comprising at least two battery modules disposed adjacent one another in a first direction within a pack housing via an air cycle system, comprising:

• providing a processor in communication with the air cycle system and at least one temperature sensor disposed on or in each of the at least two battery modules;
• operating the air cycle system, via the processor, in a first mode including passing an airflow over a first battery module in the first direction and over a second battery module in the first direction;
• receiving, at the processor, a signal from the at least one temperature sensor disposed on or in the second battery module, wherein the signal is in response to the at least one temperature sensor satisfying a temperature threshold,
• operating the air cycle system, via the processor and in response to the signal from the at least one temperature sensor, in a second mode including passing the airflow over the second battery module in a second direction, opposite the first direction and over a first battery module in the second direction.