Battery array frame design without heat sink

Abstract

A battery pack includes a heat dissipation structure, an array frame positioned against the heat dissipation structure, and a battery cell, the battery cell being held by the array frame and arranged so that at least one surface of the battery cell is exposed by the array frame and abuts the heat dissipation structure. The heat dissipation structure may be a heat exchanger plate or a thermal interface material (TIM).

Description

Technical Field

[0001] The present disclosure relates to a battery pack for an electric vehicle. An exemplary battery pack includes an array frame for holding at least one battery cell. The battery cell is positioned within the array frame such that at least one surface of the battery cell abuts a thermal interface material or heat exchanger plate of the battery pack. Background Art

[0002] The need to reduce fuel consumption and emissions from motor vehicles is obvious. As a result, vehicles are being developed that reduce or completely eliminate reliance on internal combustion engines. Electric vehicles are currently being developed for this purpose. In general, electric vehicles differ from conventional motor vehicles in that they are selectively driven by one or more battery-powered electric motors. In contrast, conventional motor vehicles rely entirely on internal combustion engines to propel the vehicle.

[0003] High voltage battery packs typically power the motors and other electrical loads of electric vehicles. The battery pack includes a plurality of battery cells that store energy for powering these electrical loads. The battery cells generate heat, for example, during charging and discharging operations. In some battery packs, the battery cells are thermally managed by using heat sinks positioned in contact with the battery cells. Summary of the invention

[0004] A battery pack according to an exemplary aspect of the present disclosure includes, among other things, a heat dissipation structure, an array frame positioned against the heat dissipation structure, and battery cells held by the array frame, and the battery cells are arranged so that at least one surface of the battery cells is exposed by the array frame and adjacent to the heat dissipation structure.

[0005] In another non-limiting embodiment of the foregoing battery pack, the heat dissipation structure is a heat exchanger plate.

[0006] In another non-limiting embodiment of any of the foregoing battery packs, the heat dissipation structure is a thermal interface material (TIM).

[0007] In another non-limiting embodiment of any of the foregoing battery packs, the TIM is disposed between a surface of the battery cell and the heat exchanger plate.

[0008] In another non-limiting embodiment of any of the foregoing battery packs, the array frame is rectangular in shape and includes a top wall, support beams, and frame arms extending between the top wall and the support beams.

[0009] In a further non-limiting embodiment of any of the foregoing battery packs, a support beam separates a first portion of a battery cell from a second portion of an adjacent battery cell.

[0010] In a further non-limiting embodiment of any of the foregoing battery packs, the support beam comprises a triangular cross-section.

[0011] In a further non-limiting embodiment of any of the foregoing battery packs, the top wall comprises a first width, and the support beam comprises a second width that is less than the first width.

[0012] In a further non-limiting embodiment of any of the foregoing battery packs, the support beam comprises a hard plastic material overmolded with a soft plastic material.

[0013] In another non-limiting embodiment of any of the foregoing battery packs, the array frame is three-sided and includes a top wall and frame arms extending from the top wall.

[0014] In another non-limiting embodiment of any of the foregoing battery packs, the surface of the battery cell is a bottom surface.

[0015] In another non-limiting embodiment of any of the foregoing battery packs, a surface of the battery cells is not completely covered by any portion of the array frame.

[0016] In another non-limiting embodiment of any of the foregoing battery packs, a battery assembly is positioned against the heat dissipation structure, the battery assembly comprising an array frame, a battery cell, and a plurality of additional array frames and battery cells.

[0017] In another non-limiting embodiment of any of the foregoing battery packs, the array frame extends along a longitudinal axis, and the thermally conductive paths of the battery cells extend parallel to the longitudinal axis along a length of a side of the battery cells.

[0018] In a further non-limiting embodiment of any of the foregoing battery packs, the array frame does not include cooling fins positioned in contact with the battery cells.

[0019] A method according to another exemplary aspect of the present disclosure includes, among other things, retaining a battery cell within an array frame of a battery assembly such that at least one surface of the battery cell abuts a thermal interface material (TIM) or a heat exchanger plate.

[0020] In another non-limiting embodiment of the foregoing method, the at least one surface is exposed through the array frame.

[0021] In another non-limiting embodiment of any of the foregoing methods, the at least one surface is a bottom surface of the battery cell.

[0022] In another non-limiting embodiment of any of the foregoing methods, wherein the battery assembly is positioned atop the heat exchanger plates, and the TIM is disposed between the battery assembly and the heat exchanger plates.

[0023] In a further non-limiting embodiment of any of the foregoing methods, the battery assembly does not include any cooling fins.

[0024] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings, including any of its various aspects or individual features, may be made independently or in any combination. Features described in conjunction with one embodiment are applicable to all embodiments, unless these features are mutually exclusive. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description.The drawings that accompany the detailed description can be briefly described as follows.

[0026] Figure 1 schematically illustrates a powertrain system for an electric vehicle;

[0027] Figure 2 A battery pack for an electric vehicle is shown;

[0028] Figure 3 An exemplary array frame of a battery assembly is shown;

[0029] Figure 4 and 5 A battery assembly including a group of battery cells and an interconnected array frame is shown;

[0030] Figure 6 It is described including Figure 4 and 5 A cross-sectional view of a portion of a battery pack of a battery assembly;

[0031] Figure 7 Another exemplary array frame of a battery assembly is shown;

[0032] Figure 8 and 9 Another battery assembly including a group of battery cells and an interconnected array frame is shown;

[0033] Fig.10 It is described including Figure 8 and 9 A cross-sectional view of a portion of a battery pack of a battery assembly. DETAILED DESCRIPTION

[0034] The present disclosure details various battery pack designs for use in electric vehicles. An exemplary battery pack includes a heat exchanger plate, an array frame positioned relative to the heat exchanger plate, a thermal interface material (TIM) disposed between the heat exchanger plate and the array frame, and battery cells held by the array frame. At least one surface of the battery cell directly contacts the heat exchanger plate or the TIM. These and other features are discussed in more detail in the following paragraphs of this specific embodiment.

[0035] Figure 1Schematically illustrated is a powertrain 10 for an electric vehicle 12. Although depicted as a hybrid electric vehicle (HEV), it should be understood that the concepts described herein are not limited to HEVs and may extend to other electric vehicles including, but not limited to, plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), fuel cell vehicles, etc.

[0036] In a non-limiting embodiment, the powertrain 10 is a power split powertrain that employs a first and a second drive system. The first drive system includes a combination of an engine 14 and a generator 18 (i.e., a first motor). The second drive system includes at least a motor 22 (i.e., a second motor), the generator 18, and a battery pack 24. In this example, the second drive system is considered to be the electric drive system of the powertrain 10. Both the first and second drive systems are capable of generating torque to drive one or more sets of vehicle drive wheels 28 of the electric vehicle 12. Although in Figure 1 A power split configuration is depicted in , but the present disclosure extends to any hybrid or electric vehicle, including a full hybrid, parallel hybrid, series hybrid, mild hybrid, or micro hybrid.

[0037] The engine 14 (which may be an internal combustion engine) and the generator 18 may be connected via a power transfer unit 30 (e.g., a planetary gear set). Of course, other types of power transfer units (including other gear sets and transmissions) may be used to connect the engine 14 to the generator 18. In a non-limiting embodiment, the power transfer unit 30 is a planetary gear set (including a ring gear 32, a sun gear 34, and a carrier assembly 36).

[0038] Generator 18 may be driven by engine 14 through power transfer unit 30 to convert kinetic energy into electrical energy. Generator 18 may alternatively be used as a motor to convert electrical energy into kinetic energy, thereby outputting torque to shaft 38 connected to power transfer unit 30. Because generator 18 is operatively connected to engine 14, the speed of engine 14 may be controlled by generator 18.

[0039] The ring gear 32 of the power transfer unit 30 can be connected to the shaft 40, which is connected to the vehicle drive wheels 28 through the second power transfer unit 44. The second power transfer unit 44 can include a gear set having a plurality of gears 46. Other power transfer units may also be suitable. The gears 46 transfer torque from the engine 14 to the differential 48 to ultimately provide traction for the vehicle drive wheels 28. The differential 48 may include a plurality of gears capable of transferring torque to the vehicle drive wheels 28. In a non-limiting embodiment, the second power transfer unit 44 is mechanically connected to the axle 50 through the differential 48 to distribute torque to the vehicle drive wheels 28.

[0040] The motor 22 can also be used to drive the vehicle drive wheels 28 by outputting torque to a shaft 52 that is also connected to the second power transfer unit 44. In a non-limiting embodiment, the motor 22 and the generator 18 cooperate as part of a regenerative braking system, wherein both the motor 22 and the generator 18 can be used as motors to output torque. For example, the motor 22 and the generator 18 can each output electrical power to the battery pack 24.

[0041] The battery pack 24 is an exemplary electric vehicle battery. The battery pack 24 may be a high voltage traction battery pack that includes a plurality of battery assemblies 25 (i.e., a battery array or battery cell group) capable of outputting electrical power to operate the motor 22, the generator 18, and / or other electrical loads of the electric vehicle 12. Other types of energy storage devices and / or output devices may also be used to power the electric vehicle 12.

[0042] In a non-limiting embodiment, the electric vehicle 12 has two basic operating modes. The electric vehicle 12 can be operated in an electric vehicle (EV) mode, in which the motor 22 is used for vehicle propulsion (generally without the assistance of the engine 14), thereby depleting the state of charge of the battery pack 24 to its maximum allowable discharge rate under a certain driving mode / cycle. The EV mode is an example of a charge-depleting operating mode of the electric vehicle 12. During the EV mode, the state of charge of the battery pack 24 may increase under some circumstances (e.g., due to a period of regenerative braking). The engine 14 is generally turned off in the default EV mode, but can be operated as needed based on vehicle system conditions or with the operator's permission.

[0043] The electric vehicle 12 may additionally operate in a hybrid electric vehicle (HEV) mode, in which both the engine 14 and the motor 22 are used for vehicle propulsion. The HEV mode is an example of a charge-maintaining operating mode of the electric vehicle 12. During the HEV mode, the electric vehicle 12 may reduce the propulsion use of the motor 22 by increasing the propulsive force of the engine 14 in order to maintain the state of charge of the battery pack 24 at a constant or approximately constant level. In addition to the EV and HEV modes within the scope of the present disclosure, the electric vehicle 12 may also operate in other operating modes.

[0044] Figure 2 A battery pack 24 that may be used in an electric vehicle is schematically shown. For example, the battery pack 24 may be Figure 1 The electric vehicle 12 is a portion of a powertrain 10 . Figure 2 is a perspective view of the battery pack 24 , and its external components (eg, the housing assembly 60 ) are shown in phantom to better illustrate some of the internal components of the battery pack 24 .

[0045] The battery pack 24 includes a plurality of battery cells 56 that store electrical power for powering various electrical loads of the electric vehicle 12. The battery pack 24 may employ any number of battery cells within the scope of the present disclosure, and the present disclosure is not limited to Figure 2 Exact configuration shown.

[0046] The battery cells 56 may be stacked side by side to build groupings of battery cells 56, sometimes referred to as "battery stacks." The battery pack 24 may include one or more individual groupings of battery cells 56. The battery cells 56 may include any geometry (prismatic, cylindrical, pouch, etc.) and any chemistry (lithium-ion, nickel metal hydride, lead acid, etc.).

[0047] The battery cells 56 together with any supporting structures (e.g., array frames, spacers, rails, walls, plates, bindings, etc.) may be collectively referred to as a battery assembly 25. In one embodiment, the battery cells 56 are held relative to each other by a plurality of interconnected array frames 58. Figure 2 The battery pack 24 is depicted as having a single battery assembly 25, but the battery pack 24 may include a greater number of battery assemblies within the scope of the present disclosure. In addition, although described as extending longitudinally within the battery pack 24, the battery pack 25 may also be optionally configured to extend laterally or horizontally within the battery pack 24.

[0048] The housing assembly 60 houses each cell assembly 25 of the battery pack 24. In a non-limiting embodiment, the housing assembly 60 is a sealed housing including a tray 62 and a cover 64. The cover 64 is secured to the tray 62 to enclose and seal the cell assemblies 25 of the battery pack 24.

[0049] Figure 3 Shows Figure 2 FIG. 5 is an exemplary array frame 58 of a battery assembly 25 of FIG. The array frame 58 includes a frame body 66 disposed along a longitudinal axis A. The frame body 66 may be rectangular in shape (i.e., having four sides) and include a top wall 68, a support beam 70, and a frame arm 72 connected between the top wall 68 and the support beam 70. In one embodiment, the frame arm 72 is disposed within the longitudinal extent of the top wall 68 and the support beam 70. The top wall 68, the support beam 70, and the frame arm 72 establish a perimeter around an opening 74 formed through the frame body 66. In one embodiment, the top wall 68 and the support beam 70 extend horizontally and parallel to the longitudinal axis A, and the frame arm 72 extends vertically and transversely to the longitudinal axis A.

[0050] The frame body 66 of the array frame 58 can be a unitary plastic structure. In a non-limiting embodiment, the top wall 68, support beams 70, and frame arms 72 are molded, cast, machined, or otherwise manufactured to form a unitary structure.

[0051] Each opposing side of the frame body 66 includes a recess 75. The recess 75 may be sized and shaped to receive a battery cell (see, e.g., Figure 4 and 5 Component 56). The array frame 58 can accommodate one or two battery cells, and each recess 75 is capable of receiving a single battery cell. In one embodiment, the battery cell 56 is a soft pack battery suitable for a high voltage battery assembly. A non-limiting example of a suitable soft pack battery cell is a lithium ion battery. However, other types of battery cells are also contemplated within the scope of the present disclosure.

[0052] In another embodiment, the top wall 68 of the frame body 66 includes a first width W1 and the support beams 70 of the frame body 66 include a second width W2. The second width W2 is a width that is smaller than the first width W1. Therefore, as discussed in more detail below, at least one surface of the battery cells held within the frame body 66 of the array frame 58 may be exposed to direct contact with other structures (e.g., heat dissipation structures).

[0053] A plurality of retaining members 76 may be integrated into the top wall 68 of the frame body 66 and / or the frame arms 72 for connecting the array frame 58 to an adjacent array frame. The retaining members 76 may engage (e.g., snap into) corresponding retaining members of an adjacent array frame to construct a battery assembly. It should be understood that the battery assembly of the present disclosure is not limited to any particular number of array frames or battery cells.

[0054] The array frame 58 may further include one or more fastener housings 78. The fastener housings 78 are an integral component of the frame body 66 of the array frame 58. The fastener housings 78 may protrude from the frame arms 72 in a direction away from the opening 74 of the frame body 66. In a non-limiting embodiment, the fastener housings 78 are disposed at both ends of the frame arms 72 (e.g., near the junction between the frame arms 72 and the top wall 68 and near the junction between the frame arms 72 and the support beam 70).

[0055] Each fastener housing 78 includes an opening 80. The opening 80 extends through the fastener housing 78. For example, the opening 80 can extend along an axis B between the opposing side walls 84, 86 of the fastener housing 78. In one embodiment, the axis B is perpendicular to the longitudinal axis A. Each opening 80 is configured to receive a rod 82 (see, for example, Figure 5 ). Rod 82 can be inserted through opening 80 of fastener housing 78 to connect array frame 58 to an additional array frame of a battery assembly. Rod 82 serves to exert compression on such a battery assembly.

[0056] Reference now Figure 4 and Figure 5, multiple array frames 58 can be stacked side by side to build a battery assembly 25. Each array frame 58 of the battery assembly 25 can accommodate two battery cells 56. The terminals 88 of the battery cells 56, once positioned within the array frame 58, protrude laterally outward from the frame arms 72 of the array frame 58. For example, the terminals 88 can be positioned vertically between the fastener housings 78 of each array frame 58.

[0057] Once received in the recesses 75 of the array frames 58, the battery cells 56 may contact each other along their sides 90. The support beams 70 of each array frame 58 may be positioned axially between two adjacent battery cells 56 of the battery assembly 25. The bottom portions of each battery cell 56 are thus separated from each other (i.e., discontinuous) by the support beams 70.

[0058] In one embodiment, Figure 5 As best shown, the support beams 70 have a triangular cross-sectional shape for retaining the battery cells 56 relative to the array frame 58. Other shapes are also contemplated within the scope of the present disclosure. The top wall 68 may also include battery cell support features.

[0059] The battery cells 56 are arranged relative to the support beams 78 such that at least one surface 92 of each battery cell 56 is exposed through the array frame 58. In one embodiment, the surface 92 is the bottom surface of the battery cell 56. To achieve this exposed design, the support beams 70 are positioned axially between adjacent battery cells 56, but do not extend below the battery cells 56.

[0060] In another embodiment, the support beam 70 is made of a harder material overmolded with a softer material. For example, the support beam 70 can be made of a relatively hard plastic material (e.g., high density polyethylene (HDPE)) overmolded with a relatively soft plastic material (e.g., polyurethane foam). Other materials are also contemplated within the scope of the present disclosure.

[0061] During certain conditions, such as charging and discharging operations, the battery cells 56 of the battery assembly 25 can generate a relatively significant amount of heat. It may be desirable to manage this heat to improve the capacity and life of the battery cells 56, and thereby improve the operation and efficiency of the battery pack 24. Some known battery assemblies use one or more heat sinks (e.g., strips of aluminum or other metallic material) received within the array frame 58 and positioned in direct contact with the battery cells 56 to manage the heat generated by the battery cells 56. However, the battery assembly 25 of the present disclosure does not include any heat sinks. Instead, as discussed in more detail below, the battery cells 56 can be thermally managed by utilizing their internal component structures.

[0062] Figure 6A portion of a battery pack 24 is shown including a battery assembly 25 having a plurality of battery cells 56 held within an array frame 58. The battery assembly 25, and therefore the battery cells 56 and array frame 58, may be positioned on top of a heat exchanger plate 94 (which may be referred to as a cooling plate). The heat exchanger plate 94 may be a housing assembly 60 (see FIG. 1 ) of the battery pack 24. Figure 2 ) or may be a separate structure located within the housing assembly 60. For example, the heat exchanger plates 94 may be made of a metallic material such as aluminum.

[0063] In one embodiment, the exposed surface 92 of each battery cell 56 is adjacent to or in direct contact with a heat exchanger plate 94. The heat exchanger plate 94 is configured to conduct heat away from the battery cells 56. In other words, the heat exchanger plate 94 acts as a heat sink to remove heat from a heat source (i.e., the battery cells 56) during certain conditions. Alternatively, the heat exchanger plate 94 can be configured to add heat to the battery cells 56 (e.g., in relatively cold ambient conditions).

[0064] In another embodiment, a thermal interface material (TIM) 96 is disposed between the battery assembly 25 and the heat exchanger plate 94 such that the exposed surfaces 92 of the battery cells 56 are in direct contact with the TIM 96. The TIM 96 maintains thermal contact between the battery cells 56 and the heat exchanger plate 94 and increases thermal conductivity between these adjacent components during a heat transfer event. The TIM 96 can be any known thermally conductive material.

[0065] As described above, heat generated by the battery cells 56 of the battery assembly 25 is thermally managed without positioning heat sinks between the battery cells 56. This can be achieved by taking advantage of the internal component structure of the battery cells 56. For example, the battery cells 56 can include internal electrode cells or folds that are wrapped around a horizontal axis that is generally parallel to the longitudinal axis A of each array frame 58. Thus, each battery cell 56 includes a thermally conductive path that extends from battery cell to battery cell along the length of the side 90 of the battery cell 56 parallel to the longitudinal axis A rather than laterally. By exposing the surface 92 through the array frame 58, the surface 92 can be positioned to directly contact the heat exchanger plate 94 or TIM 96. Because the battery cells 56 contact the heat sink along the same direction of the thermally conductive path, heat can be effectively transferred between the battery cells 56 and the heat exchanger plate 94 without the need for the use of heat sinks.

[0066] Figure 7Another exemplary array frame 158 that can be used in a battery assembly of a battery pack is shown. The array frame 158 includes a frame body 166 disposed along a longitudinal axis A. The frame body 166 can be three-sided and includes a top wall 168 and a frame arm 172 extending laterally from the top wall 168. In this embodiment, the frame body 166 is free of any support beams on the ends of the frame arms 172 opposite the top wall 168. In one embodiment, the top wall 168 extends horizontally and parallel to the longitudinal axis A, and the frame arms 172 extend vertically and transverse to the longitudinal axis A.

[0067] The frame body 166 of the array frame 58 can be a unitary plastic structure. In one embodiment, the top wall 168 and frame arms 172 are molded, cast, machined or otherwise manufactured to form a unitary structure.

[0068] Each opposing side of the frame body 66 includes a recess 175. The recess 175 may be sized and shaped to accommodate a battery cell 156 (see, e.g., Figure 8 and 9 ). The array frame 158 can accommodate one or more battery cells 156, and each recess 175 is capable of receiving a single battery cell.

[0069] The array frame 158 may additionally include one or more fastener housings 178. The fastener housings 178 are an integral component of the frame body 166 of the array frame 158. The fastener housings 178 may protrude from the frame arms 172 in a direction away from the center of the frame body 166. In a non-limiting embodiment, the fastener housings 178 are disposed at the top and bottom of the frame arms 172 (e.g., near the junction between the frame arms 172 and the top wall 168, and at the ends of the frame arms 172 opposite the junction). Each fastener housing 178 may include an opening 180 for receiving a rod or other fastener for applying compression across the battery assembly.

[0070] Reference now Figure 8 and Fig. 9 , multiple array frames 158 can be stacked side by side to build a battery assembly 125. Each array frame 158 of the battery assembly 125 can accommodate two battery cells 156. Once the battery cells 156 are received in the grooves 175 of the array frames 158, they can contact each other along their sides 190. Since the array frame 158 is three-sided and therefore does not include any bottom wall or support beams, the battery cells 156 can be arranged so that at least one surface 192 of each battery cell 156 is fully exposed to contact another structure (e.g., a heat dissipation structure). In one embodiment, the surface 192 is the bottom surface of the battery cell 156.

[0071] Fig.10A portion of a battery pack 124 including the battery assembly 125 described above is shown. The battery assembly 125, and therefore the battery cells 156 and array frame 158, can be located above or atop a heat exchanger plate 194. In one embodiment, the exposed surface 192 of each battery cell 156 is adjacent to or in direct contact with the heat exchanger plate 194. The heat exchanger plate 194 conducts heat away from the battery cells 156 to thermally manage the heat generated within the battery cells 156.

[0072] In another embodiment, a thermal interface material (TIM) 196 is disposed between the battery assembly 125 and the heat exchanger plate 194 such that the exposed surfaces 192 of the battery cells 156 are in direct contact with the TIM 196. The TIM 196 maintains thermal contact between the battery cells 156 and the heat exchanger plate 194, thereby increasing thermal conductivity between these adjacent components during a heat transfer event.

[0073] Regarding the above Figure 6 Similar to the discussed embodiments, the heat generated by the battery cells 156 of the battery assembly 125 can be thermally managed without the use of a heat sink. This can be achieved by utilizing the internal component construction of the battery cells 156. For example, the battery cells 156 can include an internal cell or folded portion that is wound around a horizontal axis that is substantially parallel to the longitudinal axis A of each array frame 158. Therefore, each battery cell 156 includes a heat conduction path extending from battery cell to battery cell along the length of the side 190 of the battery cell 156 parallel to the longitudinal axis A rather than laterally. Through the exposed surface 192 through the array frame 158 (here, at the bottom of the array frame 158), the surface 192 can be positioned to directly contact the heat exchanger plate 194 or TIM 196. Since this direct contact extends in the same direction of the heat conduction path, heat can be effectively transferred between the battery cell 156 and the heat exchanger plate 194 without the need for a heat sink.

[0074] The exemplary battery assembly of the present disclosure utilizes the internal component configuration of the battery cells to achieve sufficient heat transfer without using heat sinks positioned axially between the battery cells. Eliminating the heat sinks results in reduced cost, weight, and package size due to the ability to place the battery cells more closely.

[0075] Although different non-limiting embodiments are shown as having specific components or steps, the embodiments of the present disclosure are not limited to those specific combinations. Some components or features from any non-limiting embodiment may be used in combination with features or components from any other non-limiting embodiment.

[0076] It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings.It should be understood that although specific component arrangements are disclosed and illustrated in these exemplary embodiments, other arrangements may also benefit from the teachings of the present disclosure.

[0077] The foregoing description should be interpreted as illustrative rather than restrictive. Those of ordinary skill in the art will appreciate that certain modifications may fall within the scope of the present disclosure. For these reasons, the following claims should be studied to determine the true scope and content of the present disclosure.

Claims

1. A battery pack comprising: Heat dissipation structure; an array frame positioned against the heat dissipation structure; and a battery cell held by the array frame and arranged such that at least one surface of the battery cell is exposed by the array frame and abuts the heat dissipation structure; The array frame includes a fastener housing including openings extending therethrough, each opening being configured to receive a rod to connect the array frame to an additional array frame. 2 . The battery pack according to claim 1 , wherein the heat dissipation structure is a heat exchanger plate, or a heat exchanger plate and a thermal interface material (TIM). 3 . The battery pack according to claim 2 , wherein the thermal interface material (TIM) is disposed between the surface of the battery cell and a heat exchanger plate.

4. The battery pack of claim 1 , wherein the array frame is rectangular in shape and includes a top wall, a support beam, and a frame arm extending between the top wall and the support beam, and wherein the support beam separates a first portion of the battery cell from a second portion of an adjacent battery cell. The battery pack of claim 4 , wherein the support beam comprises a triangular cross-section. 6 . The battery pack of claim 4 , wherein the top wall comprises a first width, and the support beam comprises a second width that is less than the first width.

7. The battery pack of claim 1, wherein the array frame is three-sided and includes a top wall and frame arms extending from the top wall. The battery pack according to claim 1 , wherein the surface of the battery cell is a bottom surface.

9. The battery pack of claim 1, wherein the array frame extends along a longitudinal axis, and the thermally conductive paths of the battery cells extend parallel to the longitudinal axis along the length of the sides of the battery cells.

10. A battery pack according to any preceding claim, wherein the array frame does not include cooling fins positioned in contact with the battery cells.

11. A method for dissipating heat from a battery assembly, comprising: Holding the battery cell within an array frame of the battery assembly such that at least one surface of the battery cell abuts a thermal interface material (TIM) or a heat exchanger plate; The array frame includes a fastener housing including openings extending therethrough, each opening being configured to receive a rod to connect the array frame to an additional array frame.

12. The method of claim 11, wherein the at least one surface is exposed through the array frame.

13. The method of claim 11 or 12, wherein the at least one surface is a bottom surface of the battery cell.

14. The method according to claim 11 or 12, wherein the battery assembly is positioned on top of the heat exchanger plate, and the thermal interface material (TIM) is disposed between the battery assembly and the heat exchanger plate.

15. The method of any one of claims 11 or 12, wherein the battery assembly does not include any cooling fins.

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