Duct and a method of manufacturing a duct

Abstract

A battery pack comprises one or more cells 30, a flexible duct 50/230 positioned proximally to the surface of at least one of the one or more cells 30 such that heat can be exchanged between the duct 50/230 and at least one of the one or more cells 30 and a potting means which at least partially surrounds at least a part of the duct 50/230. A method of manufacturing a battery pack comprises providing one or more cells 30, positioning a flexible duct 50/230 proximally to the surface of at least one of the one or more cells 30 such that heat can be exchanged between the duct 50/230 and the at least one of the one or more cells 30, inserting fluid into the duct 50/230 and at least partially surrounding at least a part of the duct 50/230 with a potting means. The potting means may be expandable foam.

1 - 32 . (canceled) 
     
     
         33 . A duct capable of engaging at least part of a surface area of a heat source, the duct extendable along and engageable with at least part of the surface area of the heat source along all or part of the length of the heat source from a first engagement position to a final engagement position between the duct and heat source, wherein the duct does not come into contact with itself along the length of the duct during normal operating conditions, a heat transfer fluid flowable along an internal conduit of the duct such that heat can be transferred between the duct and the heat source via the heat transfer fluid about the engageable surface areas of the duct and the heat source, the duct being a flexible duct adapted to allow variable thermal transfer via the heat transfer fluid between the engageable surface areas of the duct and the heat source, wherein the heat source comprises a battery pack comprising: one or more cells, the battery pack comprises at least one support means configured to provide support to at least one duct, the or each support means is configured to provide support to a duct at a point where the duct changes and/or reverses direction. 
     
     
         34 . The duct as claimed in  claim 33 , wherein the duct is adapted to allow variable thermal transfer via the heat transfer fluid between the engageable surface areas of the duct and the heat source along the length of the duct. 
     
     
         35 . The duct as claimed in  claim 33 , wherein the duct is positioned proximally to the surface of the heat source such that heat can be exchanged between the duct and the heat source. 
     
     
         36 . The duct as claimed in  claim 33 , wherein the duct is positioned proximally to the surface of one or more cells such that heat can be exchanged between the duct and at least one of the one or more cells. 
     
     
         37 . The duct as claimed in  claim 33 , wherein a potting material is provided to act as a support for at least a part of the duct. 
     
     
         38 . The duct as claimed in  claim 33 , wherein the duct is configured to carry the heat transfer fluid from an inlet to an outlet to transfer thermal energy between the heat source and the duct at their engageable contact surfaces via the heat transfer fluid and wherein the thermal resistance of the duct at the inlet is higher than the thermal resistance of the duct at the outlet. 
     
     
         39 . The duct as claimed in  claim 33 , wherein the duct is configured to carry the heat transfer fluid from an inlet to an outlet to transfer thermal energy between the one or more cells and the duct at their engageable contact surfaces via the heat transfer fluid and wherein the thermal resistance of the duct at the inlet is higher than the thermal resistance of the duct at the outlet. 
     
     
         40 . The duct as claimed in  claim 33 , wherein the thermal resistance of the duct is varied linearly or non-linearly along the length of the duct such that the thermal resistance of the duct decreases as the temperature differential between the heat transfer fluid and the heat source also decreases, thereby promoting uniform power dissipation along the length of the duct. 
     
     
         41 . A duct as claimed in  claim 33 , wherein the duct is configured to carry the heat transfer fluid from an inlet to an outlet to transfer thermal energy between the heat source and the duct at their engageable contact surfaces via the heat transfer fluid and wherein the thermal resistance of the duct at the inlet is higher than the thermal resistance of the duct at the outlet; wherein the wall thickness of the duct is thicker at the inlet compared to the outlet; wherein the wall thickness of the duct varies linearly or non-linearly along a longitudinal length of the duct. 
     
     
         42 . The duct as claimed in  claim 33 , wherein the wall thickness of the duct is varied such that a substantially constant power dissipation is achieved along a longitudinal length of the duct. 
     
     
         43 . The duct as claimed in  claim 33 , wherein the duct includes a serpentine duct. 
     
     
         44 . The heat source of  claim 33  in combination with the duct as claimed in  claim 33 . 
     
     
         45 . The heat source in combination with the duct as claimed in  claim 44 , wherein the heat source and duct comprises a plurality of ducts. 
     
     
         46 . A duct and heat source assembly as claimed in  claim 44 , comprising: a heat source that includes a plurality of battery cells arranged in a plurality of rows; each row having a first end and a second end; a flexible duct located between the rows and the duct not coming into contact with itself during normal operating conditions; an inner support structure located at points where the duct bends; the duct engaging at least part of a surface area of each of the cells in each of the rows; a heat transfer fluid flowable along an internal conduit of the duct such that heat can be transferred between the duct and the cells; and the duct being having thermal transfer properties that vary along its length. 
     
     
         47 . The assembly of  claim 33 , wherein each part of the cells the duct engages has about the same length. 
     
     
         48 . The assembly of  claim 33 , further comprising an outer support structure that cooperates with the inner support structure to define a path for the duct. 
     
     
         49 . The assembly of  claim 48 , wherein the outer support structure defines a first notch spaced from a second notch to accommodate slack in the duct. 
     
     
         50 . The assembly of  claim 46 , wherein the wall thickness of the duct is thicker at the first end of the first and second rows compared to the first end of the third and fourth rows. 
     
     
         51 . The assembly of  claim 50 , wherein the wall thickness of the duct varies linearly or non-linearly along a longitudinal length of the duct.