New aluminum alloy heat exchangers and methods of making the same

Abstract

New heat exchangers for electric vehicles and methods for making the same are disclosed. The new heat exchangers may be suited for use with automotive electrical vehicle batteries. The new heat exchangers may be in the form of, for instance, one or more cooling plate assemblies. The new heat exchangers may be made from, for instance, one or more aluminum alloys. The aluminum alloys may be one or more high strength aluminum alloys. The new heat exchangers may for, for instance, at least part of an electrical vehicle battery cage suited to constrain the battery during transport.

Description

Attorney Ref. No.: 176971.119485 / WO NEW ALUMINUM ALLOY HEAT EXCHANGERS AND METHODS OF MAKING THE SAME CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 562,876, filed on March 8, 2024, entitled “NEW ALUMINUM ALLOY HEAT EXCHANGERS AND METHODS OF MAKING THE SAME,” which application is incorporated herein by reference in its entirety. BACKGROUND

[0002] Automotive electric vehicles generally produce power using batteries. Battery performance may degrade at elevated temperatures. Electrical vehicle batteries also may have a high mass, which must be constrained during transport to meet automotive safety requirements. SUMMARY OF THE DISCLOSURE

[0003] Broadly, the present patent application relates to new heat exchangers suited for use with automotive electrical vehicle batteries and methods of making and using the same. The heat exchangers may be in the form of, for instance, one or more cooling plate assemblies. The heat exchangers may be made from, for instance, one or more aluminum alloys. The aluminum alloys may be one or more high strength aluminum alloys. The heat exchangers may form, for instance, at least part of an electrical vehicle battery cage suited to constrain the battery during transport. The new heat exchangers may, for instance, realize high strength and cooling efficiency while also reducing manufacturing energy requirements and carbon emissions. In one embodiment, 5xxx and / or 6xxx aluminum alloys are employed with a heat exchanger, allowing for utilization of recycled aluminum materials, such as vehicle end-of-life scrap, and providing enhanced load bearing capabilities in the finished product (e.g., for vehicle battery tray structures). Additional details are provided below. i. Processing

[0004] Referring now to FIG.1, one non-limiting embodiment of a new method for producing a heat exchanger in the form of an aluminum alloy cooling plate assembly is illustrated. In the illustrated embodiment, the method includes joining a second aluminum alloy sheet to a first aluminum alloy sheet with a sacrificial element located therebetween (1000), then creating aAttorney Ref. No.: 176971.119485 / WO formed channel extending from a first channel opening to a second channel opening (2000), and then removing the sacrificial element from the formed channel (3000).

[0005] The joining step (1000) generally comprises joining a second aluminum alloy sheet to a first aluminum alloy sheet, wherein, as joined, a sacrificial element is located between the first aluminum alloy sheet and the second aluminum alloy sheet. The sacrificial element includes a first end portion, a second end portion, and a channel-forming portion extending from the first end portion to the second end portion along a channel path (e.g., a tortuous or non-tortuous channel path) between the first aluminum alloy sheet and the second aluminum alloy sheet. Additionally, the sacrificial element may include an interior passage extending, for example, from a first opening at the first end portion to a second opening at the second end portion. The sacrificial element may comprise graphite, a polymer, a combination thereof, or any other suitable material. The sacrificial element may comprise one material or a plurality of materials (e.g., multiple layers comprising different material compositions). The sacrificial element may be formed and positioned between the first aluminum alloy sheet in a variety of ways, as described herein.

[0006] Referring now to FIG. 8, in one embodiment, the joining step (1000) comprises positioning a sacrificial element between the first aluminum alloy sheet and the second aluminum alloy sheet (1200). In one example, the positioning step (1200) may include forming the sacrificial element separate from the first aluminum alloy sheet and the second aluminum alloy sheet (1220). The formed sacrificial element may then be positioned between the first aluminum alloy sheet and the second aluminum alloy sheet. In another example, the positioning step (1200) may include forming the sacrificial element on the first aluminum alloy sheet or the second aluminum alloy sheet (1240).

[0007] The sacrificial element may be formed using any suitable process. In one embodiment, the sacrificial element may be formed by an additive manufacturing process, such as a three- dimensional (3D) printing process, a spray forming process (e.g., cold spraying), a coating process, or any other suitable additive process. In another embodiment, the sacrificial element may be formed by molding process, such as an extrusion molding process, a blow molding process, an injection molding process, or any other suitable molding process. In yet another embodiment, portions of a formed material may be removed by, for example, a die cutting and / or forming process, a machining process, a laser cutting process, or any other suitable material removal and / or shaping process to produce an exterior profile of a sacrificial element. An interior passage may be formed within the sacrificial element during an additive manufacturing or molding process. In another embodiment, the sacrificial element may beAttorney Ref. No.: 176971.119485 / WO formed in any accordance with any suitable technique, as described herein, and an interior passage may be defined within the sacrificial element by removing material from sacrificial element through, for example, a machining process (e.g., drilling, boring, and the like), a laser removal process (e.g., laser drilling), or any other suitable material removal process. In one embodiment, the sacrificial element may be formed on the first aluminum alloy sheet or the second aluminum alloy sheet. In another embodiment, the sacrificial element may be formed separate from the first aluminum alloy sheet and the second aluminum alloy sheet.

[0008] Referring now to FIG. 9, in one embodiment, the joining step (1000) may in include one or more of solid-state bonding (1400), welding (1600), or adhesive bonding (1800). The solid-state bonding step (1400) may include roll bonding (1420), such as cold roll bonding, wherein a temperature of one or both of the aluminum alloy sheets has a temperature of from 0º to 121ºC at initiation of the bonding procedure, or hot roll bonding, wherein a temperature of one or both of the aluminum alloy sheets is at a temperature of from greater than 121ºC to 425 ºC. Welding (1600) may include, for example, ultrasonic welding (1620), laser welding (1640), arc welding, induction welding, and / or any other suitable fusion welding technique. Friction stir welding may also be employed as needed.

[0009] Referring now to FIG. 10, in one embodiment, after the joining operation (1000), the creating step (2000) generally comprises applying force to the sacrificial element to deform at least one of the first aluminum alloy sheet and the second aluminum alloy sheet (2200). The applying step (2200) may include directing a fluid (e.g., air, water, or another suitable gas, liquid, or mixture thereof) through a passage within the sacrificial element (2220) and / or directing a fluid between the sacrificial element and the first aluminum alloy sheet or the second aluminum alloy sheet (2240). The fluid may be introduced, for example, near a first end of the sacrificial element while blocking emission of the fluid downstream of the first end (e.g., using a closure device to block emission of the fluid from a second end of the sacrificial element).

[0010] Referring now to FIG. 11, in one embodiment, the applying step (2200) may include applying a first force (or pressure) to create the formed channel (2260) and then applying a second force (or pressure)to create failures in the sacrificial element (2280). Failures may be created in the sacrificial element in any suitable manner using any suitable technique or combination of techniques, including those described herein. In one embodiment, the second force is greater than the first force. In another embodiment, the second force is applied in a different direction, e.g., torsionally different, different in the axial direction, different in the longitudinal direction. The second force may be generally similar to the first force and / or the second force may be additionally applied in a different direction while the first force is applied.Attorney Ref. No.: 176971.119485 / WO In one embodiment, one or more additional forces may be applied to create failures in the sacrificial element, such as vibrational forces (e.g., mechanical vibration, sonic or ultrasonic vibration, etc.). In another embodiment, the sacrificial element may be subjected to elevated and / or reduced temperatures to create failures. For example, a material of the sacrificial element may soften and / or melt at sufficiently high temperatures. In one embodiment, the sacrificial element may include a thermoplastic material that softens and / or melts at elevated temperatures (e.g., temperatures greater than a glass transition temperature and / or a melting temperature of the material), facilitating the creation of failures in the sacrificial element by heating the sacrificial element above the glass transition or melting temperature. In another embodiment, the sacrificial element may comprise a phase-change material that melts at its phase-change temperature, enabling the creation of failures by heating the sacrificial element to at least the phase-change temperature. In yet another embodiment, a material of the sacrificial element may become brittle at sufficiently low temperatures, facilitating the creation of failures in the sacrificial element by exposing the sacrificial element to decreased temperatures. In another embodiment, the sacrificial element may comprise a non-Newtonian fluid that, for example, expands without failing under some conditions (e.g., when a first force is consistently applied and / or gradually increased) and fails when exposed to additional forces (e.g., when a second force is rapidly applied and / or increased and / or when the second force is a different type of force and / or is applied in a different direction than the first force).

[0011] Referring now to FIG. 12, after the creating step (2000), the removing step (3000) generally comprises removing the sacrificial element. The sacrificial element may be removed from the formed channel in any suitable manner using any suitable technique or combination of techniques, including those described herein. In some embodiments, the step of creating failures in the sacrificial element (2280) can occur concomitantly with the removing step (3000). In one embodiment, the removing step (3000) includes flushing material of the sacrificial element from the formed channel (3200). For example, a gas and / or liquid may be flowed through the formed channel to flush material of the sacrificial element from the formed channel. In one embodiment, a solvent (e.g., water) may at least partially dissolve the sacrificial element. In other embodiments, a gas (e.g., air) may be flowed through the formed channel to remove at least a portion of the sacrificial element from the formed channel. In one example, failures created in the sacrificial element may at least partially facilitate dissolution and / or removal of at least a portion the sacrificial element from the formed channel. In some examples, heat and / or vibration may be applied to the sacrificial element (e.g., via the first aluminum alloy sheet, the second aluminum alloy sheet, and / or a fluid passed through the formed channel)Attorney Ref. No.: 176971.119485 / WO to facilitate failure, dissolution, and / or removal of the sacrificial element. In another embodiment, one or more of the techniques described above for creating failures in the sacrificial element may additionally or alternatively be used to facilitate removal of the sacrificial element. ii. Composition

[0012] The first aluminum alloy sheet and the second aluminum alloy sheet may each be any suitable aluminum alloy, such as any of a 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx or 8xxx aluminum alloy. In one embodiment, the first aluminum alloy sheet comprises a first aluminum alloy composition and the second aluminum alloy sheet comprises a second aluminum alloy composition. In one embodiment, the first aluminum alloy composition is the same as the second aluminum alloy composition. For instance, the first aluminum alloy composition may be a 5xxx aluminum alloy, such as 5182, and the second aluminum alloy composition may be the same 5xxx aluminum alloy, such as 5182. In another embodiment, the first aluminum alloy composition is different than the second aluminum alloy composition. For instance, the first aluminum alloy composition may be a 5xxx aluminum alloy, such as 5182, and the second aluminum alloy composition may be a different 5xxx aluminum alloy, such as 5083. As another example, the first aluminum alloy composition may be a 5xxx aluminum alloy, such as 5182, and the second aluminum alloy composition may be the same 6xxx aluminum alloy, such as 6013.

[0013] In one embodiment, the first aluminum alloy sheet and / or the second aluminum alloy sheet comprise a 5xxx aluminum alloy or a 6xxx aluminum alloy. The 5xxx aluminum alloy may be any suitable 5xxx aluminum alloy, such as any of the 5xxx aluminum alloys registered with the Aluminum Association. In one embodiment, a 5xxx aluminum alloys comprises (and in some instances consists essentially of or consists of) from 0.5 wt. % to 2.5 wt. % Mg. In one embodiment, a 5xxx aluminum alloy includes from 0.5 wt. % to 2.5 wt. % Mg, from 0 wt. % to 0.5 wt. % Fe, from 0 wt. % to 0.15 wt. % Cu, from 0 wt. % to 0.3 wt. % Mn, and no or essentially no Li, with the balance generally being aluminum, optional incidental elements and impurities.

[0014] The 6xxx aluminum alloy may be any suitable 6xxx aluminum alloy, such as any of the 6xxx aluminum alloys registered with the Aluminum Association. In one embodiment, a 6xxx aluminum alloys comprise (and in some instances consist essentially of or consist of) from 0.4 to 1.5 wt. % Si and from 0.4 to 1.5 wt. % Mg. In one embodiment, a 6xxx aluminum alloy includes from 0.4 to 1.5 wt. % Si, from 0.40 to 1.5 wt. % Mg, from 0.05 to 0.4 wt. % Fe, fromAttorney Ref. No.: 176971.119485 / WO 0.05 to 0.35 wt. % Mn, from 0.1 to 0.80 wt. % Cu, from 0 to 0.1 wt. % Cr, and from 0 to 0.10 wt. % Ti, with the balance generally being aluminum, optional incidental elements and impurities.

[0015] As noted above, the balance of a 5xxx or 6xxx aluminum alloys is generally aluminum, optional incidental elements and impurities. As used herein, “incidental elements” means those elements or materials, other than the above listed elements, that may optionally be added to the alloy to assist in the production of the alloy. Examples of incidental elements include casting aids, such as grain refiners and deoxidizers. Optional incidental elements may be included in the alloy in a cumulative amount of up to 1.0 wt. %. As one non-limiting example, one or more incidental elements may be added to the alloy during casting to reduce or restrict (and in some instances eliminate) ingot cracking due to, for example, oxide fold, pit and oxide patches. These types of incidental elements are generally referred to herein as deoxidizers. Examples of some deoxidizers include Ca, Sr, and Be. When calcium (Ca) is included in the alloy, it is generally present in an amount of up to about 0.05 wt. %, or up to about 0.03 wt. %. In some embodiments, Ca is included in the alloy in an amount of about 0.001-0.03 wt. %, such as 0.001-0.008 wt. % (or 10 to 80 ppm). Strontium (Sr) may be included in the alloy as a substitute for Ca (in whole or in part), and thus may be included in the alloy in the same or similar amounts as Ca. Traditionally, beryllium (Be) additions have helped to reduce the tendency of ingot cracking, though for environmental, health and safety reasons, some embodiments of the alloy are substantially Be-free. When Be is included in the alloy, it is generally present in an amount of up to about 20 ppm. Incidental elements may be present in minor amounts, or may be present in significant amounts, and may add desirable or other characteristics on their own without departing from the alloy described herein, so long as the alloy retains the desirable characteristics described herein. It is to be understood, however, that the scope of this disclosure should not / cannot be avoided through the mere addition of an element or elements in quantities that would not otherwise impact on the combinations of properties desired and attained herein.

[0016] The aluminum alloys may contain low amounts of impurities. In one embodiment, a 5xxx or 6xxx aluminum alloy includes not greater than 0.15 wt. %, in total, of the impurities, and wherein the 5xxx or 6xxx aluminum alloy includes not greater than 0.05 wt. % of each of the impurities. In another embodiment, a 5xxx or 6xxx aluminum alloy includes not greater than 0.10 wt. %, in total, of the impurities, and wherein the 5xxx or 6xxx aluminum alloy includes not greater than 0.03 wt. % of each of the impurities.Attorney Ref. No.: 176971.119485 / WO

[0017] The first aluminum alloy sheet and the second aluminum alloy sheet may comprise any suitable aluminum alloy materials and / or combination of aluminum alloy materials. In one embodiment, the first aluminum alloy sheet comprises a 5xxx aluminum alloy and the second aluminum alloy sheet comprises a 5xxx aluminum alloy. In another embodiment, the first aluminum alloy sheet comprises a 5xxx aluminum alloy and the second aluminum alloy sheet comprises a 6xxx aluminum alloy. In yet another embodiment, the first aluminum alloy sheet comprises a 6xxx aluminum alloy and the second aluminum alloy sheet comprises a 6xxx aluminum alloy. In another embodiment, the first aluminum alloy sheet comprises a 5xxx aluminum alloy and the second aluminum alloy sheet comprises a 1xxx, 2xxx, 3xxx, 4xxx, 7xxx or 8xxx aluminum alloy. In yet another embodiment, the first aluminum alloy sheet comprises a 6xxx aluminum alloy and the second aluminum alloy sheet comprises a 1xxx, 2xxx, 3xxx, 4xxx, 7xxx or 8xxx aluminum alloy. In another embodiment, the first aluminum alloy sheet comprises a 1xxx, 2xxx, 3xxx, 4xxx, 7xxx or 8xxx aluminum alloy and the second aluminum alloy sheet comprises a 1xxx, 2xxx, 3xxx, 4xxx, 7xxx or 8xxx aluminum alloy.

[0018] Except where stated otherwise, the expression “up to” when referring to the amount of an element means that that elemental composition is optional and includes a zero amount of that particular compositional component. Unless stated otherwise, all compositional percentages are in weight percent (wt. %). iii. Product Applications

[0019] The new heat exchangers described herein may be used in a variety of applications, such as in heat exchange units for automotive cooling applications, among others. Indeed, in some embodiments, due to the use of high strength aluminum alloys, the new heat exchangers may be used for both cooling of one or more batteries of an electrical vehicle while also acting as a constraint or cage for the one or more batteries. Thus, non-limiting examples of heat exchange units include heat exchange units for cooling electrical components used in automotive vehicles, such as batteries used in electric vehicles or hybrid vehicles. One example of an automotive heat exchange unit may include a battery cold plate, which is an apparatus that is positioned along a battery surface or between batteries in a battery stack and that includes one or more internal channels that direct cooling liquid or air for removing heat from the batteries. The new heat exchangers may be used in any other suitable transportation applications, such as electric or hybrid light or heavy trucks. The new heat exchangers may be used in any other suitable applications utilizing a heat exchange unit, such as commercial and consumer electronics cooling applications.Attorney Ref. No.: 176971.119485 / WO iv. Definitions

[0020] “Wrought aluminum alloy product” means an aluminum alloy product that is hot worked after casting, and includes rolled products (sheet or plate), forged products, and extruded products.

[0021] “Hot working” such as by hot rolling means working the aluminum alloy product at elevated temperature, and generally at least 121.1℃ (250ºF). Strain-hardening is restricted / avoided during hot working, which generally differentiates hot working from cold working.

[0022] “Cold working” such as by cold rolling means working the aluminum alloy product at temperatures that are not considered hot working temperatures, generally below about 121.1℃ (250ºF) (e.g., at ambient).

[0023] Temper definitions are per ANSI H35.1 (2009), entitled “American National Standard Alloy and Temper Designation Systems for Aluminum,” published by The Aluminum Association.

[0024] Strength and elongation are measured in accordance with ASTM E8 / E8M-16a and B557-15.

[0025] Aluminum alloy compositions are per the “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys,” published by the Aluminum Association, 1525 Wilson Boulevard, Arlington, VA, 22209. v. Miscellaneous

[0026] These and other aspects, advantages, and novel features of this new technology are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the following description and figures, or may be learned by practicing one or more embodiments of the technology provided for by the present disclosure.

[0027] Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention is intended to be illustrative, and not restrictive.

[0028] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases “in oneAttorney Ref. No.: 176971.119485 / WO embodiment” and “in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though they may. Furthermore, the phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although they may. Thus, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.

[0029] In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and / or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise. The meaning of “in” includes “in” and “on”, unless the context clearly dictates otherwise.

[0030] While a number of embodiments of the present invention have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art. Further still, unless the context clearly requires otherwise, the various steps may be carried out in any desired order, and any applicable steps may be added and / or eliminated. BRIEF DESCRIPTION OF DRAWINGS

[0031] FIG. 1 is a process flow diagram illustrating one embodiment of a method for manufacturing a heat exchanger comprising a cooling plate assembly in accordance with embodiments herein.

[0032] FIG. 2a is a top view illustrating one embodiment of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0033] FIG. 2b is a top view illustrating a portion of one embodiment of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0034] FIG. 2c is a top view illustrating a portion of one embodiment of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0035] FIG. 2d is a top view illustrating a portion of one embodiment of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0036] FIG. 3 is a cross-sectional side view illustrating a portion of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0037] FIG. 4 is a cross-sectional side view illustrating a portion of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.Attorney Ref. No.: 176971.119485 / WO

[0038] FIG. 5a is a cross-sectional side view illustrating a portion of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0039] FIG. 5b is a cross-sectional side view illustrating a portion of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0040] FIG. 6 is a cross-sectional side view illustrating a portion of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0041] FIG. 7 is a cross-sectional side view illustrating a portion of a heat exchanger comprising an aluminum alloy cooling plate assembly in accordance with embodiments herein.

[0042] FIG. 8 is a process flow diagram illustrating embodiments relating to the aluminum alloy sheet joining step (1000) of FIG.1.

[0043] FIG. 9 is a process flow diagram illustrating embodiments relating to the aluminum alloy sheet joining step (1000) of FIG.1.

[0044] FIG. 10 is a process flow diagram illustrating embodiments relating to the channel creating step (2000) of FIG.1.

[0045] FIG. 11 is a process flow diagram illustrating embodiments relating to the channel creating step (2000) of FIG.1.

[0046] FIG. 12 is a process flow diagram illustrating embodiments relating to the sacrificial element removing step (3000) of FIG.1. DETAILED DESCRIPTION

[0047] The following examples are intended to illustrate the invention and should not be construed as limiting the invention in any way.

[0048] Referring now to FIG.2a, one non-limiting embodiment of an example heat exchanger in the form of an aluminum alloy cooling plate assembly (100) is illustrated. In the illustrated embodiment, the cooling plate assembly (100) includes a pair of aluminum alloy sheets (110) with a sacrificial element (120) located between the pair of aluminum alloy sheets (110). The sacrificial element (120) may have a first end portion (122a) and a second end portion (122b) and a channel-forming portion (122c) extending from the first end portion (122a) to the second end portion (122b) along a channel path (114a) between the pair of aluminum alloy sheets. The channel-forming portion (122c) may follow any suitable channel path, such as a tortuous channel path (114a) as illustrated.

[0049] The pair of aluminum alloy sheets (110) may define a sheet perimeter (116). Each of the first end portion (122a) and the second end portion (122b) of the sacrificial element (120) may be located external to or at least partially within the sheet perimeter (116). For example,Attorney Ref. No.: 176971.119485 / WO in the embodiment illustrated in FIG.2a, the first end portion (122a) and the second end portion (122b) are both wholly or at least partially located outside the sheet perimeter (116).

[0050] In accordance with described embodiments, during the joining step (1000), the pair of aluminum alloy sheets (110) may be joined, wherein, as joined, the sacrificial element (120) is located between the pair of aluminum alloy sheets (110). In the example shown in FIG. 2a, non-channel regions (114b) of the pair of aluminum alloy sheets (110) may not overlap the channel-forming portion (122c) of the sacrificial element (120). The pair of aluminum alloy sheets (110) may be joined, for example, by bonding the pair of aluminum alloy sheets (110) at the non-channel regions (114b).

[0051] During the creating step (2000), a formed channel extending from a first channel opening (118a) to a second channel opening (118b) may be created between the joined pair of aluminum alloy sheets (110). The formed channel may, for example, follow the tortuous channel path (114a). In one embodiment, the first channel opening (118a) and the second channel opening (118b) may be located at the sheet perimeter (116) of the pair of aluminum alloy sheets (110) and the formed channel may be in fluid communication with the first channel opening (118a) and the second channel opening (118b). The creating step (2000) may include applying a force to the sacrificial element (120) to deform at least one of the pair of joined aluminum alloy sheets (110), thereby forming the formed channel. In one embodiment, the creating step (2000) may include introducing a fluid near a first end of the sacrificial element (120) and blocking emission of the fluid downstream of the first end, thereby applying the force to the sacrificial element (120).

[0052] Referring now to FIG. 2b, a portion of one non-limiting embodiment of an example aluminum alloy cooling plate assembly (100) is illustrated. In the illustrated embodiment, an outlet (126) is positioned between the pair of aluminum alloy sheets (110). The outlet (126) may be in communication with a fluid source, such as a fluid supply line (128), which may deliver a fluid from any suitable pressurized fluid supply, such as a pump, a compressor, a reservoir, or the like. The outlet (126) may include an outlet of any member or device capable of positioning the outlet (126) between the pair of aluminum alloy sheets (110). For example, as illustrated, a nozzle (124) fluidly connected to the fluid supply line (128) may include the outlet (126) at an end. In the embodiment illustrated in FIG. 2b, the outlet (126) may be positioned within an end of the sacrificial element (120). For example, the nozzle (124) may be inserted through a first element opening (132a) at first end portion (122a) of the sacrificial element (120) so that the outlet (126) is positioned within the first end portion (122a) of theAttorney Ref. No.: 176971.119485 / WO sacrificial element (120). In this embodiment, the nozzle (124) may form a seal with a portion of the sacrificial element (120), such as portion at or near first element opening (132a).

[0053] In the example illustrated in FIG. 2b, when the outlet is positioned within the first end of the sacrificial element (120), a second end of the sacrificial element (120) may be blocked to block emission of a fluid downstream of the first end. For example, as illustrated, a blocking member (130) may be located at or near the second end portion (122b). The blocking member may include, for example, a clamp or other suitable closure device configured to prevent passage of fluid from the sacrificial element (120) and / or from between the pair of aluminum alloy sheets (110) downstream of the first end. For example, the blocking member (130) may close a portion of a fluid passage within the sacrificial element (120) to block emission of fluid from a second element opening (132b) at the second end of the sacrificial element (120) and / or to block emission of fluid from an opening between the pair of aluminum alloy sheets (110) proximal the second end portion (122b) of the sacrificial element (120) (e.g., second channel opening (118b) illustrated in FIG.2a).

[0054] Referring now to FIG. 2c, a portion of one non-limiting embodiment of an example aluminum alloy cooling plate assembly (100) is illustrated. One or both ends of the sacrificial element may be at least partially located within or wholly located inside the sheet perimeter (116). For example, in the illustrated embodiment, the first end portion (122a) and the second end portion (122b) of the sacrificial element (120) are each wholly located within the sheet perimeter (116). An adapter may be coupled to at least one end of the sacrificial element (120). In the example illustrated, a first adapter (134a) is coupled to the first end portion (122a) and a second adapter (134b) is coupled to the second end portion (122b). The adapter(s) may be coupled to the sacrificial element (120) at any suitable time. For example, the first adapter (134a) and the second adapter (134b) may be coupled to the sacrificial element (120) prior to the creating step (2000).

[0055] Adapters coupled to ends of the sacrificial element (120) may each be located external to or at least partially within the sheet perimeter (116) of the pair of aluminum alloy sheets (110). For example, as illustrated in FIG. 2c, each of the first adapter (134a) and the second adapter (134b) may include a portion near an end of the sacrificial element (120) that is disposed within the sheet perimeter (116) and another portion that is disposed outside the sheet perimeter (116) so as to protrude from the sheet perimeter (116). Each of the first adapter (134a) and the second adapter (134b) may include an internal passage configured to allow for passage of a fluid and / or a fluid delivery outlet (e.g., outlet (126) of nozzle (124) illustrated in FIG.2b). For example, the first adapter (134a) may include a passage that extends from a first adapterAttorney Ref. No.: 176971.119485 / WO opening (136a) to the first end portion (122a) of the sacrificial element (120) and the second adapter (134b) may include a passage that extends from a second adapter opening (136b) to the second end portion (122b) of the sacrificial element (120).

[0056] Referring now to FIG. 2d, a portion of one non-limiting embodiment of an example aluminum alloy cooling plate assembly (100) is illustrated. In the illustrated embodiment, the first end portion (122a) and the second end portion (122b) of the sacrificial element (120) are each at least partially or wholly located external to the sheet perimeter (116). Additionally, in this embodiment, adapters coupled to the ends of the sacrificial element (120) are located wholly outside the sheet perimeter. For example, as shown, a first adapter (140a) is coupled to the first end portion (122a) and a second adapter (140b) is coupled to the second end portion (122b) of the sacrificial element (120). Each adapter may include an internal passage configured to allow for passage of a fluid. For example, the first adapter (140a) may include a passage that extends from a first adapter opening (142a) to the first end portion (122a) of the sacrificial element (120) and the second adapter (140b) may include a passage that extends from a second adapter opening (142b) to the second end portion (122b) of the sacrificial element (120).

[0057] In some examples, an outlet, such as the outlet (126) of the nozzle (124) illustrated in FIG. 2b, may be positioned within an adapter. For example, the outlet (126) may be inserted through the first adapter opening (136a) of the first adapter (134a) shown in FIG. 2c so as to be positioned within the first adapter (134a). In an additional embodiment, the outlet (126) may be inserted through the first adapter opening (142a) of the first adapter (140a) shown in FIG. 2d so as to be positioned within the first adapter (140a). In some examples, the outlet (126) may be inserted within an adapter so at be positioned within the sheet perimeter (116). In at least one example, the outlet (126) may be inserted through an adapter so at be positioned within an end of the sacrificial element (120) within the sheet perimeter (116). An adapter may comprise any suitable material. For example, the first adapter (134a), the second adapter (134b), the first adapter (140a), and / or the second adapter (140b) may include a material having greater rigidity than a material of the sacrificial element (120).

[0058] Referring now to FIG. 3, a portion of one non-limiting embodiment of an example aluminum alloy cooling plate assembly (100) is illustrated. As illustrated, a pair of aluminum alloy sheets (e.g., the pair of aluminum alloy sheets (110) illustrated in FIG.2a) may include a first aluminum alloy sheet (110a) and a second aluminum alloy sheet (110b). The illustrated cross-sectional view shows the channel-forming portion (122c) of the sacrificial element (120). The sacrificial element (120) may include an outer element surface (146) and an elementAttorney Ref. No.: 176971.119485 / WO passage (144) defined within the sacrificial element (120). The element passage (144) may extend within the sacrificial element (120) from a first end to a second end (e.g., the first end portion (122a) and the second end portion (122b) of the sacrificial element (120) illustrated in FIG.2b).

[0059] As illustrated in FIG. 3, prior to or during the joining step (1000), the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be positioned in an overlapping arrangement with the sacrificial element (120) disposed therebetween. For example, the sacrificial element (120) may be positioned between a first inner sheet surface (148a) of the first aluminum alloy sheet (110a) and the second inner sheet surface (148b) of the second aluminum alloy sheet (110b). Prior to the joining step (1000), the first inner sheet surface (148a) may be spaced apart from the second inner sheet surface (148b) by the sacrificial element (120). The first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may each have any suitable thickness. For example, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may each have respective thicknesses T1a and T1b of from 0.5 to 6.0 mm.

[0060] As noted above, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 0.5 mm. In one embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 1 mm. In another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 1.5 mm. In another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 2.0 mm. In yet another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 2.5 mm. In another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 3.0 mm. In yet another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of at least 3.5 mm.

[0061] As noted above, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of not greater than 6.0 mm. In one embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of not greater than 5.5 mm. In another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of not greater than 5.0 mm. In another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of not greater than 4.5 mm. In yet anotherAttorney Ref. No.: 176971.119485 / WO embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may have a thickness of not greater than 4.0 mm.

[0062] The first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may each include any suitable aluminum alloy as described above, such as a 5xxx or 6xxx aluminum alloy. In one embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) may comprise a high-strength aluminum alloy, such as a 5xxx, 6xxx aluminum alloy, or any other suitable aluminum alloy, having a tensile yield strength of at least 60 Mpa. In one embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) realizes a tensile yield strength of at least 80 Mpa. In another embodiment, the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) realizes a tensile yield strength of at least 100 Mpa.

[0063] The sacrificial element (120) may include any suitable material. In one example, the sacrificial element (120) substantially comprises or consists essentially of a graphite material. In at least one example, the sacrificial element (120) may also include one or more other materials either alone or in combination with the graphite material. For example, the sacrificial element (120) may comprise a polymer material and / or one or more other suitable materials. The sacrificial element (120) may be formed in any suitable manner. For example, the sacrificial element (120) may be produced by an additive manufacturing process (e.g., a 3D printing process, a spray forming process, a coating process) and / or a molding process (e.g., an extrusion molding process, a blow molding process, an injection molding process, or any other suitable molding process). In one embodiment, portions of a formed material may be removed to form and / or define at least a portion sacrificial element (120). Portions of the material for forming sacrificial element (120) may be removed by, for example, a die cutting and / or forming process, a machining process, a laser cutting process, or any other suitable material removal and / or shaping process. An interior passage may be formed within the sacrificial element during an additive manufacturing or molding process. In another embodiment, an interior passage may be defined within the sacrificial element by removing material from sacrificial element through, for example, a machining process (e.g., drilling, boring), a laser removal process (e.g., laser drilling), or any other suitable material removal process.

[0064] In one embodiment, the sacrificial element (120) may be formed on the first aluminum alloy sheet (110a) or the second aluminum alloy sheet (110b). In an additional embodiment, the sacrificial element (120) may be formed at a location separate from the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b). The separately formed sacrificialAttorney Ref. No.: 176971.119485 / WO element (120) may then be positioned between the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b).

[0065] Referring now to FIG. 4, a portion of one non-limiting embodiment of an example aluminum alloy cooling plate assembly (100) is illustrated. As illustrated, following the joining step (1000) and prior to the creating step (2000), the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be joined together. In the joined state illustrated in FIG.4, portions of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) in non-channel region (114b) may be joined at an interface (150) between the first inner sheet surface (148a) of the first aluminum alloy sheet (110a) and the second inner sheet surface (148b) of the second aluminum alloy sheet (110b). Additionally, portions of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) overlapping the channel path (114a) may be separated from each other by the sacrificial element (120).

[0066] In some embodiments, the joining step (1000) may include solid-state bonding the first aluminum alloy sheet (110a) to the second aluminum alloy sheet (110b). For example, the joining step (1000) may include roll bonding the first aluminum alloy sheet to the second aluminum alloy sheet. In one embodiment, the roll bonding includes a cold roll bonding step, wherein, at initiation of the cold roll bonding step, a temperature of the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) is from 0º to 121ºC. In an additional embodiment, the joining step (1000) may include a hot roll bonding step in addition to or instead of the cold roll bonding step. At initiation of the hot roll bonding step, a temperature of the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) is greater than 121ºC. Further, at initiation of the hot roll bonding step, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may each have a temperature that is not greater than 425ºC. In some embodiments, the joining step (1000) may include welding or adhesive bonding the first aluminum alloy sheet (110a) to the second aluminum alloy sheet (110b). Following the joining step (1000), the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may each have respective thicknesses T2a and T2b of from 0.5-4 mm, from 0.5-3 mm, or from 0.5-2 mm.

[0067] Referring now to FIG. 5a, one non-limiting embodiment of a portion of an example aluminum alloy cooling plate assembly (100) is illustrated. During the creating step (2000), force may be applied to the sacrificial element (120) to deform at least one of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b), thereby forming a formed channel (152) between the first aluminum alloy sheet (110a) and the second aluminum alloyAttorney Ref. No.: 176971.119485 / WO sheet (110b). In the illustrated embodiment, the formed channel (152) is formed around the sacrificial element (120).

[0068] In some embodiments, the force may be applied by a fluid within the element passage (144) in the sacrificial element (120). The fluid may be introduced in any suitable manner. For example, an outlet (e.g., the outlet (126) of the nozzle (124) illustrated in FIG. 2b) may be utilized to introduce a fluid within the element passage (144) of the sacrificial element (120). The fluid may be any suitable liquid or gas. For example, the fluid may include a gas comprising at least one of air and an air-based mixture. In other embodiments, the fluid may include a liquid, such as a solvent or other suitable liquid. In one embodiment, the fluid may comprise a solvent and the sacrificial element (120) may be at least partially soluble in the solvent. Additionally, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be inert to the solvent. In one embodiment, the liquid may comprise at least one of water and an aqueous mixture.

[0069] In some examples, applying the force may expand the channel forming portion (122c) of the sacrificial element (120) surrounding the element passage (144), thereby forcing the channel forming portion (122c) of the sacrificial element (120) against abutting portions the first inner sheet surface (148a) of the first aluminum alloy sheet (110a) and the second inner sheet surface (148b) of the second aluminum alloy sheet (110b). As the channel forming portion (122c) of the sacrificial element (120) is forced against inner surfaces of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b), regions of the first aluminum alloy sheet (110a) and / or the second aluminum alloy sheet (110b) surrounding the sacrificial element (120) may be forced outward to conform to an external profile of the expanded sacrificial element (120). In the example illustrated in FIG.5a, at least a first portion of the formed channel (152) may be at least partially defined by the first inner sheet surface (148a) of the first aluminum alloy sheet (110a) and at least a second portion of the formed channel (152) may be at least partially defined by the second inner sheet surface (148b) of the second aluminum alloy sheet (110b).

[0070] The formed channel (152) may extend along a path followed by the sacrificial element (120) (e.g., channel path (114a) illustrated in FIG.2a). Additionally, the formed channel (152) may be in fluid communication with channel openings (e.g., first channel opening (118a) and second channel opening (118b) illustrated in FIG. 2a) located at peripheral regions of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b). During the creation of the formed channel (152), portions of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) in the non-channel region (114b) may remain joined at theAttorney Ref. No.: 176971.119485 / WO interface (150) between the first inner sheet surface (148a) of the first aluminum alloy sheet (110a) and the second inner sheet surface (148b) of the second aluminum alloy sheet (110b).

[0071] In accordance with one embodiment, the sacrificial element (120) may be configured to expand at a first force and may be configured to fail at a second force greater than the first force. In this embodiment, prior to the creating step (2000), the sacrificial element (120) may be preselected, wherein the preselecting includes selecting a material that expands at the first force and purposely fails at the second force. Following preselection of the sacrificial element (120), the creating step (2000) may include applying the first force to the sacrificial element (120), thereby creating the formed channel (152), as illustrated in FIG.5a.

[0072] While FIG.5a shows, for purposes of illustration, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) deformed to substantially the same extent about formed channel (152), in an additional embodiment, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be deformed differently about formed channel (152). For example, the first aluminum alloy sheet (110a) may be deformed to a greater or lesser extend than the second aluminum alloy sheet (110b). In one embodiment, one of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be deformed and the other of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may experience little or no deformation. The materials and / or thicknesses of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be chosen to produce a selected degree of deformation in each of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) during the creating step (2000). In one embodiment, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may each comprise substantially the same material and / or may have substantially the thickness, resulting in the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) being deformed in substantially the same manner and to substantially the same extent.

[0073] In another embodiment, the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may differ in material and / or thickness, resulting in the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) being deformed to different extents, with the formed channel (152) protruding to a greater extent on a side of the first aluminum alloy sheet (110a) or the second aluminum alloy sheet (110b). For example, the first aluminum alloy sheet (110a) may comprise a more rigid aluminum alloy material than the second aluminum alloy sheet (110b) such that the second aluminum alloy sheet (110b) is deformed to a greater extent when a force is applied to the sacrificial element (120). In another embodiment, the first aluminum alloy sheet (110a) may have a greater thickness than the second aluminumAttorney Ref. No.: 176971.119485 / WO alloy sheet (110b) such that the second aluminum alloy sheet (110b) is deformed to a greater extent when a force is applied to the sacrificial element (120).

[0074] Referring now to FIG. 5b, one non-limiting embodiment of a portion of an example aluminum alloy cooling plate cooling plate assembly (100) is illustrated. Failures may be created in the sacrificial element (120) in any suitable manner. In one embodiment, following application of the first force to the sacrificial element (120), the creating step (2000) may further include applying the second force to the sacrificial element (120), thereby creating failures in the sacrificial element (120). For example, as illustrated in FIG. 5b, failures (154) may be created in the sacrificial element (120) during application of the second force as the sacrificial element (120) is forced outward with increased force against the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b). In additional embodiments, the second force may be applied in a different direction, e.g., torsionally different, different in the axial direction, different in the longitudinal direction. In one embodiment, the second force may be generally similar to the first force and / or the second force may be additionally applied in a different direction while the first force is applied.

[0075] In one embodiment, one or more additional forces may be applied to create failures in the sacrificial element (120), such as vibrational forces (e.g., mechanical vibration, sonic or ultrasonic vibration, etc.). In another embodiment, the sacrificial element (120) may be subjected to elevated and / or reduced temperatures to create failures. For example, the sacrificial element (120) may include a thermoplastic material or a phase-change material. In yet another embodiment, a material of the sacrificial element (120) may become brittle at sufficiently low temperatures, facilitating the creation of failures in the sacrificial element (120) by exposing the sacrificial element (120) to decreased temperatures. In another embodiment, the sacrificial element (120) may comprise a non-Newtonian fluid that, for example, expands without failing when exposed to some forces, such as the first force, and fails when exposed to an additional force, such as the second force.

[0076] In some examples, the failures (154) may facilitate subsequent removal of at least a portion of the sacrificial element (120). For example, the failures (154) may result in the breaking up and degradation of at least a portion of the sacrificial element (120), allowing for removal of smaller pieces of the sacrificial element (120) and / or more ready dissolution of the sacrificial element (120) in a solvent due to increased exposed surface area of the sacrificial element (120). In some embodiments, the step of creating failures in the sacrificial element (2280) can occur concomitantly with the removing step (3000). In some embodiments, heat and / or vibration may be applied to the sacrificial element (120) (e.g., via the first aluminumAttorney Ref. No.: 176971.119485 / WO alloy sheet (110a), the second aluminum alloy sheet (110b), and / or a fluid passed through the formed channel (152)) to facilitate failure, dissolution, and / or removal of the sacrificial element (120) from the formed channel (152). In another embodiment, one or more of the techniques described above for creating failures in the sacrificial element (120) may additionally or alternatively be used to facilitate removal of the sacrificial element (120) from the formed channel (152).

[0077] Referring now to FIG. 6, one non-limiting embodiment of a portion of an example aluminum alloy cooling plate cooling plate assembly (100) is illustrated. In some embodiments, following the creating step (2000), the force applied to the sacrificial element (120) may be reduced (e.g., by reducing force applied by a fluid source and / or allowing emission of fluid from a previously blocked end portion of the sacrificial element (120)). Accordingly, the sacrificial element (120) may no longer be forced under force against the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b). In some examples, the sacrificial element (120) may contract and / or deform inward away from portions of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) surrounding the formed channel (152) so that at least a portion of the sacrificial element (120) is separated from the first inner sheet surface (148a) and the second inner sheet surface (148b). Additionally or alternatively, at least a portion of the sacrificial element (120) may remain in contact with and / or in close proximity to portions of the first inner sheet surface (148a) and / or the second inner sheet surface (148b).

[0078] Referring now to FIG.7, one non-limiting embodiment of an example aluminum alloy cooling plate assembly (100) following removal of a sacrificial element is illustrated. During the removing step (3000), the sacrificial element (120) may be removed from the formed channel (152). In some examples, a fluid may be used to remove the sacrificial element (120). For example, a gas and / or liquid may be flowed through the formed channel (152) to remove at least a portion of the sacrificial element (120). In one embodiment, a solvent (e.g., water) may at least partially dissolve the sacrificial element (120). In other embodiments, a gas (e.g., air) may be flowed through the formed channel (152) to carry at least a portion of the sacrificial element (120) from the formed channel (152). Failures created in the sacrificial element (120) during the creating step (2000) may at least partially facilitate dissolution and / or removal of at least a portion the sacrificial element (120) from the formed channel (152).

[0079] In some embodiments, one or both of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be further processed prior to, during, and / or following manufacturing of the aluminum alloy cooling plate assembly (100). For example, at least oneAttorney Ref. No.: 176971.119485 / WO of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) may be tempered prior to and / or after the joining step (1000). In one embodiment, at least one of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) comprises a 5xxx aluminum alloy and the tempering step comprises processing the 5xxx aluminum alloy to one of a F, O, or H temper before or after the joining step (1000). In another embodiment, at least one of the first aluminum alloy sheet (110a) and the second aluminum alloy sheet (110b) comprises a 6xxx aluminum alloy and the tempering step comprises solution heat treating the 6xxx aluminum alloy before or after the joining step (1000). The tempering step may comprise, for example, quenching and / or pre-aging the 6xxx aluminum alloy before or after the joining step (1000). In another embodiment, the tempering step comprises artificial aging the 6xxx aluminum alloy before or after the joining step (1000). The artificial aging may, for example, include paint baking. In one embodiment, the tempering step comprises processing the 6xxx aluminum alloy to one of a T4, T43, or T6 temper.

[0080] While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure.

Claims

Attorney Ref. No.: 176971.119485 / WO CLAIMS What is claimed is:

1. A method comprising: (a) joining a second aluminum alloy sheet to a first aluminum alloy sheet, wherein, as joined, a sacrificial element is located between the first aluminum alloy sheet and the second aluminum alloy sheet, the sacrificial element comprising: (i) a first end portion and a second end portion; and (ii) a channel-forming portion extending from the first end portion to the second end portion along a channel path between the first aluminum alloy sheet and the second aluminum alloy sheet; (b) creating a formed channel extending from a first channel opening to a second channel opening, wherein the creating step comprises applying a force to the sacrificial element to deform at least one of the first aluminum alloy sheet and the second aluminum alloy sheet, thereby forming the formed channel, wherein, as formed: (i) the formed channel is in fluid communication with the first channel opening and the second channel opening; (ii) at least a first portion of the formed channel is at least partially defined by an inner surface of the first aluminum alloy sheet; and (iii) at least a second portion of the formed channel is at least partially defined by an inner surface of the second aluminum alloy sheet; and (c) removing the sacrificial element from the formed channel.

2. The method of claim 1, wherein: the sacrificial element is configured to expand at a first force; and the sacrificial element is configured to fail at a second force that is different than the first force.

3. The method of claim 2, further comprising, prior to the creating step (b), preselecting the sacrificial element, wherein the preselecting comprises selecting a material that expands at the first force and purposely fails at the second force.

4. The method of claim 2 or 3, wherein the creating step (b) further comprises: applying the first force to the sacrificial element, thereby creating the formed channel; and applying the second force to the sacrificial element, thereby creating failures in the sacrificial element.Attorney Ref. No.: 176971.119485 / WO 5. The method of any one of claims 2 to 4, wherein the removing step (c) is at least partially facilitated due to the failures in the sacrificial element.

6. The method of any one of the preceding claims, wherein, the creating step (b) further comprises introducing a fluid near a first end of the sacrificial element and blocking emission of the fluid downstream of the first end.

7. The method of claim 6, wherein the blocking occurs proximal a second end of the sacrificial element.

8. The method of any one of the preceding claims, wherein the creating step (b) further comprises positioning an outlet between the first aluminum alloy sheet and the second aluminum alloy sheet, wherein the outlet is in communication with a fluid source.

9. The method of claim 8, wherein the creating step (b) further comprises positioning the outlet within an end of the sacrificial element.

10. The method of any one of the preceding claims, wherein, as joined, the first aluminum alloy sheet and the second aluminum alloy sheet define a sheet perimeter, and wherein, prior to the removing step (c), a first end of the sacrificial element is located external to or at least partially within the sheet perimeter.

11. The method of claim 10, wherein the first end is wholly located outside the sheet perimeter.

12. The method of claim 10, wherein the first end is at least partially located within the sheet perimeter.

13. The method of claim 10 or 12, wherein the first end is wholly located inside the sheet perimeter.

14. The method of any one of the preceding claims, further comprising, prior to the creating step (b), coupling an adapter to at least one end of the sacrificial element, wherein, as joined, the first aluminum alloy sheet and the second aluminum alloy sheet define a sheet perimeter, and wherein the adapter is located external to or at least partially within the sheet perimeter.

15. The method of claim 14, wherein the adapter is wholly located outside the sheet perimeter.

16. The method of claim 14, wherein the adapter is at least partially located within the sheet perimeter.

17. The method of any one of claims 14 to 16, wherein the creating step (b) further comprises positioning an outlet within the adapter, wherein the outlet is in communication with a fluid source.

18. The method of any one of claims 14 to 17, wherein the adapter comprises a material having greater rigidity than a material of the sacrificial element.Attorney Ref. No.: 176971.119485 / WO 19. The method of any one of the preceding claims, wherein the applying a force step further comprises applying the force using a fluid.

20. The method of claim 19, wherein the applying the force step comprises expanding the channel forming portion of the sacrificial element by the fluid to force the channel forming portion of the sacrificial element against an inner surface of the first aluminum alloy sheet and an inner surface of the second aluminum alloy sheet.

21. The method of claim 19 or 20, wherein the fluid comprises a gas.

22. The method of claim 21, wherein the gas comprises at least one of air and an air-based mixture.

23. The method of claim 19 or 20, wherein the fluid comprises a liquid.

24. The method of claim 23, wherein the liquid comprises a solvent and wherein the sacrificial element is at least partially soluble in the solvent.

25. The method of claim 24, wherein the first aluminum alloy sheet and the second aluminum alloy sheet are inert to the solvent.

26. The method of any one of claims 23 to 25, wherein the liquid comprises at least one of water and an aqueous mixture.

27. The method of any one of the preceding claims, wherein at least one of the first aluminum alloy sheet and the second aluminum alloy sheet comprises a high-strength alloy having a tensile yield strength of at least 60 Mpa, or at least 80 Mpa, or at least 100 Mpa.

28. The method of any one of the preceding claims, wherein at least one of the first aluminum alloy sheet and the second aluminum alloy sheet comprises a 5xxx or a 6xxx aluminum alloy.

29. The method of any one of the preceding claims, wherein the joining step (a) comprises solid-state bonding the first aluminum alloy sheet to the second aluminum alloy sheet.

30. The method of any one of the preceding claims, wherein the joining step (a) comprises roll bonding the first aluminum alloy sheet to the second aluminum alloy sheet.

31. The method of claim 30, wherein the roll bonding comprises a cold roll bonding step, wherein, at initiation of the cold roll bonding step, a temperature of the first aluminum alloy sheet is from 0º to 121ºC.

32. The method of claim 31, wherein, at initiation of the cold roll bonding step, a temperature of the second aluminum alloy sheet is from 0º to 121ºC.

33. The method of any one of claims 30 to 32, wherein the roll bonding comprises a hot roll bonding step, wherein, at initiation of the hot roll bonding step, a temperature of the first aluminum alloy sheet is greater than 121ºC.Attorney Ref. No.: 176971.119485 / WO 34. The method of claim 33, wherein, at initiation of the hot roll bonding step, a temperature of the second aluminum alloy sheet is greater than 121ºC.

35. The method of claim 33 or 34, wherein, at initiation of the hot roll bonding step, the first aluminum alloy sheet and the second aluminum alloy sheet each have a temperature that is not greater than 425ºC.

36. The method of any one of claims 1 to 28, wherein the joining step (a) comprises welding or adhesive bonding the first aluminum alloy sheet to the second aluminum alloy sheet.

37. The method of any one of the preceding claims, further comprising tempering at least one of the first aluminum alloy sheet and the second aluminum alloy sheet.

38. The method of claim 37, wherein the tempering occurs prior to the joining step (a).

39. The method of claim 37, wherein the tempering occurs after the joining step (a).

40. The method of any one of claims 37 to 39, wherein: at least one of the first aluminum alloy sheet and the second aluminum alloy sheet comprises a 5xxx aluminum alloy; and the tempering comprises processing the 5xxx aluminum alloy to one of a F, O, or H temper before or after the joining step (a).

41. The method of any one of claims 37 to 39, wherein: at least one of the first aluminum alloy sheet and the second aluminum alloy sheet comprises a 6xxx aluminum alloy; and the tempering comprises solution heat treating the 6xxx aluminum alloy before or after the joining step (a).

42. The method of claim 41, wherein the tempering comprises quenching and / or pre-aging the 6xxx aluminum alloy before or after the joining step (a).

43. The method of claim 41, wherein the tempering comprises artificial aging the 6xxx aluminum alloy before or after the joining step (a).

44. The method of claim 43, wherein the artificial aging comprises paint baking.

45. The method of any one of claim 41 to 44, wherein the tempering comprises processing the 6xxx aluminum alloy to one of a T4, T43, or T6 temper.

46. The method of any one of the preceding claims, wherein the removing step (c) comprises flushing material of the sacrificial element from the formed channel using a fluid.

47. The method of any one of the preceding claims, wherein the sacrificial element comprises or consists essentially of a graphite material.

48. The method of any one of the preceding claims, wherein the sacrificial element comprises a polymer material.Attorney Ref. No.: 176971.119485 / WO 49. The method of any one of the preceding claims, further comprising, prior to the joining step (a), positioning the sacrificial element between the first aluminum alloy sheet and the second aluminum alloy sheet.

50. The method of any one of the preceding claims, further comprising, prior to the joining step (a), forming the sacrificial element on the first aluminum alloy sheet or the second aluminum alloy sheet.

51. The method of any one of claims 1 to 49, further comprising, prior to the joining step (a): forming the sacrificial element at a location separate from the first aluminum alloy sheet and the second aluminum alloy sheet; and positioning the formed sacrificial element between the first aluminum alloy sheet and the second aluminum alloy sheet.

52. The method of any one of the preceding claims, wherein at least one of the first aluminum alloy sheet and the second aluminum alloy sheet has a thickness of from 0.5-4 mm, from 0.5- 3 mm, or from 0.5-2 mm.

53. The method of any one of the preceding claims, wherein the formed channel follows a tortuous path.

54. The method of any one of claims 1-52, wherein the formed channel follows a non-tortuous path.

54. A heat-exchanger made by the method of any one of the preceding claims.

55. The heat-exchanger of claim 54, wherein the heat-exchanger is a battery cooling plate assembly for an automotive vehicle.

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