Coolant reservoir and circulation assemblies and systems

Abstract

A battery coolant reservoir assembly can include an exterior structure having an interior surface defining an interior space, a flexible coolant retaining pouch coupled to a manifold, and a battery module disposed within the coolant retaining pouch. The coolant retaining pouch can be disposed in the interior space of the exterior structure. Related systems and methods are also provided.

1 . A method for making a coolant pouch, comprising:
 providing a first multi-layer liner;   providing a second multi-layer liner;   laying the first multi-layer liner flat on top of the second multi-layer liner; and   sealing at least some edges of the first multi-layer liner with edges of the second multi-layer liner.   
     
     
         2 . The method of  claim 1  wherein the sealing includes:
 sealing a proximal end of the first multi-layer with a proximal end of the second multi-layer liner; and 
 sealing two lateral sides of the first multi-layer liner with two lateral sides of the second multi-layer liner. 
 
     
     
         3 . The method of  claim 2 , further comprising:
 after sealing at least some edges of the first multi-layer liner with edges of the second multi-layer liner, coupling a manifold to the coolant pouch.   
     
     
         4 . The method of  claim 3  wherein the manifold is coupled to distal ends of the first multi-layer liner and second multi-layer liner. 
     
     
         5 . The method of  claim 1  wherein either of the first multi-layer liner or the second multi-layer liner includes:
 a first layer comprising polyethylene; 
 a second layer comprising nylon; 
 a third layer comprising aluminum; and 
 a fourth layer comprising polyethylene terephthalate. 
 
     
     
         6 . The method of  claim 2  wherein the sealing of the proximal end of the first multi-layer with the proximal end of the second multi-layer liner; and
 sealing two lateral sides of the first multi-layer liner with two lateral sides of the second multi-layer liner is completed by heat sealing. 
 
     
     
         7 . The method of  claim 3  wherein the manifold is surrounded by a heating element. 
     
     
         8 . The method of  claim 7  wherein the heating element is employed to seal the multi-layer liner surrounding the manifold. 
     
     
         9 . The method of  claim 2  wherein the proximal end of the coolant pouch is positioned on top of a battery and coolant reservoir package. 
     
     
         10 . A method for making a coolant pouch, comprising:
 providing a first multi-layer liner;   providing a second multi-layer liner;   laying the first multi-layer liner flat on top of the second multi-layer liner;   sealing at least some edges of the first multi-layer liner with edges of the second multi-layer liner; and   inserting a battery module into the coolant pouch through a distal end of the coolant pouch.   
     
     
         11 . The method of  claim 10  wherein after inserting the battery module into the coolant pouch, sealing the coolant pouch towards the distal end of the coolant pouch along a sealing line. 
     
     
         12 . The method of  claim 11  wherein the coolant pouch is selectively sealed toward the distal end to minimize an interior void between the battery module and the sealing line. 
     
     
         13 . The method of  claim 11  wherein the coolant pouch is selectively sealed toward the distal end to ensure a volume of a coolant in the pouch to regulate temperature. 
     
     
         14 . The method of  claim 10  wherein the battery module inserted into the coolant pouch comprises a plurality of conductive lines. 
     
     
         15 . The method of  claim 14  wherein during insertion of the battery module into the coolant pouch, the plurality of conductive lines is threaded through a plurality of wiring ports of a manifold. 
     
     
         16 . The method of  claim 15  further comprising sealing the plurality of wiring ports at the manifold to prevent coolant leakage. 
     
     
         17 . The method of  claim 14  wherein the plurality of conductive lines is connected to a plurality of terminal posts. 
     
     
         18 . The method of  claim 10 , further comprising:
 after inserting the battery module into the coolant pouch through the distal end of the coolant pouch, folding excess portions of the multi-layer liners.   
     
     
         19 . The method of  claim 18  further comprising inserting a plurality of coolant tube fittings into a plurality of ports of the manifold, wherein sealed battery wires extend out of the plurality of wiring ports. 
     
     
         20 . The method of  claim 19  wherein the plurality of coolant tube fittings is configured to supply to, and discharge from, a battery and coolant reservoir package.