Cold plate

Abstract

Aspects of the present disclosure relate to various features of a cold plate for a battery module. The battery module may be implemented in an electric vehicle or a building. The cold plate may include an intermediate plate including one or more openings at or near a fluid inlet configured to allow a cooling fluid to be introduced into the cold plate on a first side of the intermediate plate and simultaneously flow on both sides of the intermediate plate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 511,609, filed on June 30, 2023, entitled “Battery Subassembly,” the disclosure of which is hereby incorporated herein in its entirety. Background Art

[0003] Thermally conductive structures may be used to thermally couple a cooling source to a component or other object such as a battery cell that desires cooling.

[0004] Aspects of the subject technology may help improve the efficiency and / or range of electric vehicles, which may help mitigate climate change by reducing greenhouse gas emissions. Summary of the invention

[0005] The present disclosure is generally directed to various aspects of cold plates, such as cold plates for battery subassemblies. For example, aspects of the present disclosure include features of cold plate thermal, alignment, and / or structural features.

[0006] According to aspects of the subject technology, a device is provided that includes a plate that includes a serpentine flow path for a thermal fluid from an inlet port to an outlet port. The plate may include a plurality of structural features extending across the serpentine flow path.

[0007] The plurality of structural features may increase the burst pressure threshold of the cold plate. The plurality of structural features may separate a plurality of sub-channels of the serpentine flow path. The sub-channels may be defined in part by the plurality of structural features and may define the serpentine flow path on the first side of the plate.

[0008] The plurality of structural features may each extend from a bottom surface of a corresponding subchannel to a corresponding ridge. Each ridge may form an additional subchannel of an additional serpentine flow path on an opposite second side of the plate. The plate may also include a plurality of openings that allow the thermal fluid to flow through the plate between the serpentine flow path on the first side of the plate and the additional serpentine flow path on the opposite second side of the plate.

[0009] The first group of openings of the plurality of openings may be arranged in a first row, the first row extending diagonally from the first corner of the plate away from the first edge and the second edge of the plate defining the first corner. The second group of openings of the plurality of openings may be arranged in a second row, the second row extending diagonally from the second corner of the plate toward the inner end of the first row and away from the second edge and the third edge of the plate defining the second corner. The third group of openings of the plurality of openings may be arranged in a third row, the third row extending diagonally from the third corner of the plate away from the third edge and the fourth edge of the plate defining the third corner. The fourth group of openings of the plurality of openings may be arranged in a fourth row, the fourth row extending from a position along the fourth edge of the plate toward the inner end of the third row. The plurality of openings may be located at one or more corners in the serpentine flow path.

[0010] The plate may include an intermediate plate of a cold plate, the cold plate being formed by a top plate, a bottom plate, and the intermediate plate disposed between the top plate and the bottom plate. The cold plate may also include a flange extending along an edge of the cold plate outside the serpentine flow path, and the flange may include one or more positioning features for attaching the cold plate to one or more unit carriers. The flange may also include one or more reference features configured to facilitate alignment of the battery module with one or more structures of the battery pack. The device may also include a plurality of battery cells, each battery cell being disposed within the outer boundary of the thermal contact surface of the cold plate. The cold plate may be disposed between two groups of battery cells in an electric vehicle.

[0011] The plurality of structural features may include a structural feature formed as a segment, the segment including a first segment extending from the inlet port to the first central portion of the plate, and a second segment extending perpendicularly to the first segment from the first central portion of the plate to the second central portion. The structural feature formed as a segment may also include a third segment extending perpendicularly to the first segment and parallel to the first segment from the second central portion to the first edge portion of the plate, and a fourth segment extending perpendicularly to the third segment from the first edge portion to the first corner of the plate. The structural feature formed as a segment may also include a fifth segment extending perpendicularly to the fourth segment and parallel to the third segment from the first corner of the plate to the second corner of the plate, a sixth segment extending perpendicularly to the fifth segment from the second corner of the plate to the third corner, and a seventh segment extending perpendicularly to the sixth segment from the third corner of the plate to the outlet portion.

[0012] According to aspects of the subject technology, a thermal component is provided that includes an intermediate plate defining a serpentine flow path for a cooling fluid from an inlet port to an outlet port. The intermediate plate may include a plurality of structural features extending across the serpentine flow path.

[0013] According to aspects of the subject technology, a method is provided, comprising: providing a fluid into a cold plate on a first side of an intermediate plate of the cold plate; and facilitating simultaneous initiation of the fluid flow through a first serpentine flow path on the first side of the intermediate plate and a second serpentine flow path on an opposite second side of the intermediate plate. Facilitating the simultaneous initiation of the flow may include allowing the fluid to flow from the first side of the intermediate plate to the opposite second side of the intermediate plate through one or more openings in the intermediate plate located at or near an inlet port of the cold plate. The method may also include allowing the fluid to flow from the first side of the intermediate plate to the opposite second side of the intermediate plate or from the opposite second side of the intermediate plate to the first side of the intermediate plate through one or more additional openings in the intermediate plate located at a turn in the first serpentine flow path. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Certain features of the subject technology are set forth in the appended claims. However, for purposes of explanation, several embodiments of the subject technology are set forth in the following figures.

[0015] Figure 1A and Figure 1B A schematic perspective side view of an exemplary implementation of a vehicle having a battery pack according to one or more implementations is illustrated.

[0016] Figure 1C Schematic perspective views of buildings with battery packs are illustrated according to one or more implementations.

[0017] Figure 2A Schematic perspective views of battery packs according to one or more implementations are illustrated.

[0018] Figure 2B Schematic perspective views of various battery modules that may be included in a battery pack according to one or more implementations are illustrated.

[0019] Figure 2C A cross-sectional end view of a battery cell according to one or more implementations is illustrated.

[0020] Figure 2D A cutaway perspective view of a cylindrical battery cell according to one or more implementations is illustrated.

[0021] Figure 2E A cross-sectional perspective view of a prismatic battery cell is illustrated according to one or more implementations.

[0022] Figure 2F A cross-sectional perspective view of a pouch-shaped battery cell according to one or more implementations is illustrated.

[0023] Figure 3 A perspective view of a battery module according to one or more implementations is illustrated.

[0024] Figure 4 The invention illustrates a method according to one or more specific implementations. Figure 3 An exploded perspective view of a battery module.

[0025] Figure 5 A top perspective view of a cold plate according to one or more implementations is illustrated.

[0026] Figure 6 A top view of a portion of a cold plate according to one or more implementations is illustrated.

[0027] Figure 7 A cross-sectional side view of a cold plate according to one or more implementations is illustrated.

[0028] Figure 8 A perspective view of a portion of a middle plate of a cold plate near an opening in the middle plate is illustrated according to one or more implementations.

[0029] Fig. 9 A cross-sectional view of a portion of a flange of a cold plate according to one or more implementations is illustrated.

[0030] Fig.10 A side view of a portion of a cold plate attached to a battery cell is illustrated according to one or more implementations.

[0031] Fig.11 A perspective bottom view of a partially assembled battery module having a cold plate with locating features is illustrated according to one or more implementations.

[0032] Fig.12 A top view of a cold plate with locating features is illustrated according to one or more implementations.

[0033] Fig.13 A top view of a portion of a cold plate having an opening in a middle plate according to one or more implementations is illustrated.

[0034] Fig.14 is a flow chart of illustrative operations that may be performed to provide thermal control utilizing a cold plate in accordance with one or more implementations. DETAILED DESCRIPTION

[0035] The specific embodiments set forth below are intended to be described as various configurations of the subject technology, and are not intended to represent the only configurations that can practice the subject technology. The accompanying drawings are incorporated herein and constitute a part of the specific embodiments. The specific embodiments include specific details in order to provide a thorough understanding of the subject technology. However, the subject technology is not limited to the specific details set forth herein, and one or more other specific implementations can be used to practice. In one or more specific implementations, well-known structures and components are shown in block diagram form to avoid confusion to the concepts of the subject technology.

[0036] Various aspects of the subject technology described herein relate to cold plates, such as cold plates for battery subassemblies (eg, battery modules). Further details of various aspects of the cold plate are described below.

[0037] Figure 1A is a diagram illustrating an exemplary implementation of a device such as a mobile device described herein. Figure 1A In the example of FIG. 1 , the mobile device is implemented as a vehicle 100. As shown, the vehicle 100 may include one or more battery packs, such as a battery pack 110. The battery pack 110 may be coupled to one or more power systems of the vehicle 100 to provide power to the power systems.

[0038] In one or more implementations, the vehicle 100 may be an electric vehicle having one or more electric motors that drive the vehicle's wheels 102 using electricity from a battery pack 110. In one or more implementations, the vehicle 100 may also or alternatively include one or more chemically powered engines, such as a gasoline powered engine or a fuel cell powered motor. For example, the electric vehicle may be fully electric or partially electric (e.g., a hybrid or plug-in hybrid).

[0039] exist Figure 1A In the example of FIG. 1 , the vehicle 100 is implemented as a truck (e.g., a pickup truck) having a battery pack 110. As shown, the battery pack 110 may include one or more battery modules 115, which may include one or more battery cells 120. Figure 1AAs shown, the battery pack 110 may also or alternatively include one or more battery cells 120 directly mounted in the battery pack 110 (e.g., in a battery cell-battery pack configuration). In one or more specific implementations, the provided battery pack 110 may not have any battery modules 115, but instead have battery cells 120 directly mounted in the battery pack 110 (e.g., in a battery cell-battery pack configuration) and / or in other battery devices disposed in the battery pack 110. The vehicle battery pack may include a plurality of energy storage devices that may be arranged such as battery modules or battery devices. The battery device or module may include a battery assembly that can be combined with other elements (e.g., a structural frame, a thermal management device) that can protect the battery assembly from heat, shock, and / or vibration.

[0040] For example, the battery unit 120 may include a battery, a battery subassembly, a battery cell, a battery module, and / or a battery pack to power components of the vehicle 100. For example, a battery cell housing of the battery unit 120 may be disposed in a battery module 115, a battery pack 110, a battery array, or other battery device disposed in the vehicle 100.

[0041] As discussed in further detail below, the battery cell 120 may have a battery cell housing that may have any of a variety of external shapes. In some embodiments (e.g., for cylindrical or prismatic battery cells), the battery cell housing may be a rigid housing. In some embodiments, the battery cell housing may also or alternatively be formed as a bag or other flexible or extensible housing for the battery cell. In various other embodiments, the battery cell housing may have any other suitable external shape, such as a triangular external shape, a square external shape, a rectangular external shape, a pentagonal external shape, a hexagonal external shape, or any other suitable external shape. In some embodiments, the battery pack 110 may not include a module (e.g., the battery pack may be module-free). For example, the battery pack 110 may have a module-free or battery cell-battery pack configuration, in which the battery cells 120 are directly arranged into the battery pack 110 without being assembled into a battery module 115. In one or more implementations, the vehicle 100 may include one or more bus bars, electrical connectors, or other charge collection, current collection, and / or coupling components to provide power from the battery pack 110 to various systems or components of the vehicle 100. In one or more implementations, the vehicle 100 may include control circuitry such as a power stage circuit that may be used to convert DC power from the battery pack 110 to AC power for one or more components and / or systems of the vehicle (e.g., including one or more power outlets of the vehicle and / or a motor driving the vehicle wheels 102). The power stage circuitry may be provided as part of the battery pack 110 or may be disposed within the vehicle 100 separately from the battery pack 110.

[0042] Figure 1AThe example of is merely illustrative, in which the vehicle 100 is implemented as a pickup truck having a cabin at the rear thereof. For example, Figure 1B Another specific implementation is illustrated in which the vehicle 100 including the battery pack 110 is implemented as a sport utility vehicle (SUV), such as an electric sport utility vehicle. Figure 1B In the example of FIG. 1 , the vehicle 100 including the battery pack 110 may include a cargo storage area enclosed within the vehicle 100 (e.g., behind a row of seats within the vehicle cabin). In other specific implementations, the vehicle 100 may be implemented as another type of electric truck, electric van, electric car, electric car, electric motorcycle, electric scooter, electric bicycle, electric passenger vehicle, electric passenger or commercial truck, hybrid vehicle, aircraft, watercraft, and / or any other mobile device having a battery pack 110 (e.g., the battery pack is a battery pack or other battery device that powers a propulsion or drive component of the mobile device).

[0043] In one or more specific implementations, a battery pack such as battery pack 110, battery module 115, battery cell 120, and / or any other battery device as described herein may also or alternatively be implemented as a power supply and / or energy storage system in a building such as a residential or commercial building. For example, Figure 1C An example of a battery pack 110 implemented in a building 180 is illustrated. For example, the building 180 may be a residential building, a commercial building, or any other building. As shown, in one or more specific implementations, the battery pack 110 may be mounted to a wall of the building 180.

[0044] As shown, the battery 110A installed in the building 180 may be coupled to the battery pack 110 in the vehicle 100, such as via a cable / connector 106 that may be connected to the charging port 130 of the vehicle 100, an electric vehicle supply equipment 170 (EVSE), a power stage circuit 172, and / or a cable / connector 174. For example, the cable / connector 106 may be coupled to the EVSE 170, which may be coupled to the battery 110A via the power stage circuit 172, and / or may be coupled to an external power source 190. In this way, in some use cases, the external power source 190 or the battery 110A installed in the building 180 may be used as an external power source to charge the battery pack 110 in the vehicle 100. In some examples, the battery 110A installed in the building 180 may also or alternatively be coupled (e.g., via the cable / connector 174, the power stage circuit 172, and the EVSE 170) to the external power source 190. For example, the external power source 190 may be a solar power source, a wind power source, and / or an electrical grid in a city, town, or other geographic area (e.g., an electrical grid powered by a remote power plant). During a time when, for example, the battery pack 110 in the vehicle 100 is not coupled to the battery 110A installed in the building 180, the battery 110A installed in the building 180 may be coupled (e.g., using the power stage circuit 172 of the building 180) to the external power source 190 to charge and store electrical energy. In some use cases, this stored electrical energy in the battery 110A installed in the building 180 may be used later to charge the battery pack 110 in the vehicle 100 (e.g., during times when solar or wind power is unavailable, in the event of a regional or local power outage in the building 180, and / or during high-rate time periods for accessing the grid).

[0045] In one or more implementations, the power stage circuit 172 may electrically couple the battery 110A installed in the building 180 to the power system of the building 180. For example, the power stage circuit 172 may convert DC power from the battery 110A into AC power for one or more loads in the building 180. For example, the battery 110A installed in the building 180 may be used to power one or more lighting, lights, appliances, fans, heaters, air conditioners, and / or any other electrical components or loads in the building 180 (e.g., via one or more electrical outlets coupled to the battery 110A installed in the building 180). For example, the power stage circuit 172 may include a control circuit that is operable to switchably couple the battery 110A between the external power source 190 and one or more electrical outlets and / or other electrical loads in the power system of the building 180. In one or more implementations, the vehicle 100 may include the power stage circuit ( Figure 1C), the power stage circuit may be used to convert power received from electric vehicle supply equipment 170 into DC power for powering / charging battery pack 110 of vehicle 100, and / or to convert DC power from battery pack 110 into AC power for one or more electrical systems, components and / or loads of vehicle 100.

[0046] In one or more use cases, the battery 110A installed in the building 180 can be used as a source of power for the building 180, such as during times when solar or wind power is unavailable, in the event of a regional or local power outage in the building 180, and / or during a high-rate time period for accessing the grid (as an example). In one or more other use cases, the battery pack 110 installed in the vehicle can be used to charge the battery 110A installed in the building 180 and / or to power the power system of the building 180 (e.g., in use cases where the stored energy of the battery 110A installed in the building 180 is insufficient or depleted and solar or wind power is unavailable, a regional or local power outage occurs in the building 180, and / or a high-rate time period for accessing the grid occurs (as an example)).

[0047] Figure 2A An exemplary battery pack 110 is depicted. The battery pack 110 may include a plurality of battery cells 120 (e.g., mounted directly within the battery pack 110, or mounted within a battery, battery device, and / or battery module 115, as described herein) and / or battery modules 115, and one or more conductive coupling elements for coupling the voltage generated by the battery cells 120 to power consuming components of the power system of the vehicle 100 and / or building 180, such as one or more conductive coupling elements. For example, the conductive coupling elements may include internal connectors and / or contactors that couple together the plurality of battery cells 120, battery devices, batteries, and / or a plurality of battery modules 115 within the battery pack frame 205 to generate a desired output voltage for the battery pack 110. The battery pack 110 may also include one or more external connection ports, such as an electrical contact 203 (e.g., a high voltage terminal). For example, a power cable (e.g., cable / connector 106) may be connected between the electrical contact 203 and the power system of the vehicle 100 or building 180 to provide power to the vehicle 100 or building 180.

[0048] As shown, the battery pack 110 may include a battery pack frame 205 (e.g., a battery pack housing or pack frame). For example, the battery pack frame 205 may house or enclose one or more battery modules 115 and / or one or more battery cells 120 and / or other battery pack components. In one or more specific implementations, the battery pack frame 205 may include or form a shielding structure on its outer surface (e.g., its bottom and / or under one or more battery modules 115, battery devices, batteries, and / or battery cells 120) to protect the battery modules 115, battery devices, batteries, and / or battery cells 120 from external conditions (e.g., if the battery pack 110 is installed in the vehicle 100 and the vehicle 100 is driven on rough terrain such as off-road terrain, ditches, rocks, rivers, streams, etc.).

[0049] In one or more implementations, the battery pack 110 may include one or more thermal control structures 207 (e.g., cooling lines and / or plates and / or heating lines and / or plates). For example, the thermal control structures 207 may couple thermal control structures and / or fluids to the battery modules 115, battery devices, batteries, and / or battery cells 120 within the battery pack frame 205, such as by distributing the fluid through the battery pack 110.

[0050] For example, the thermal control structure 207 may form part of a thermal / temperature control or heat exchange system that includes one or more thermal components 281, such as plates (e.g., cold plates) or bladders, that are disposed in thermal contact with one or more battery modules 115, battery cells 120, and / or other battery subassemblies disposed within the battery pack frame 205. For example, the thermal component 281 may include one or more cold plates positioned in contact with one or more battery modules 115, battery cells, battery subassemblies, batteries, and / or battery cells 120 within the battery pack frame 205. In one or more specific implementations, the battery pack 110 may include one or more thermal control structures 207 and / or other thermal components for each of a number of top and bottom battery module pairs. As shown, the battery pack 110 may include an electrical contact 203 (e.g., a high voltage connector) through which an external load (e.g., the electrical system of the vehicle 100 or the building 180) may be electrically coupled to the battery modules and / or battery cells in the battery pack 110.

[0051] Figure 2B The battery pack 110 (e.g., Figure 2A Various examples of battery modules 115 within a battery pack frame 205. Figure 2BIn the example of , a battery module 115A is shown, which includes a battery module housing 223 having a rectangular cube shape with a length approximately similar to the width. In this example, the battery module 115A includes a plurality of battery cells 120 implemented as cylindrical battery cells. In this example, the battery module 115A includes rows and columns of cylindrical battery cells coupled together by an interconnect structure 200 (e.g., a collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together, and / or couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115A may include a charge collector or busbar 202. For example, the busbar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115A.

[0052] Figure 2B Also shown are battery modules 115B having an elongated shape, wherein the length of the battery module housing 223 (e.g., extending in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., a lateral direction in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110). For example, one or more battery modules 115B may span the entire front-to-back length of the battery pack within the battery pack frame 205. As shown, the battery module 115B may also include a bus bar 202 electrically coupled to the interconnect structure 200. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115B.

[0053] In the implementation of battery module 115A and battery module 115B, battery cell 120 is implemented as a cylindrical battery cell. However, in other implementations, the battery module may include battery cells having other form factors, such as battery cells having a right prism outer shape (e.g., prismatic cells), or pouch cell implementations of battery cells. For example, Figure 2BAlso shown is a battery module 115C having a battery module housing 223 having a rectangular cube shape having a length that is approximately similar to the width and including a plurality of battery cells 120 implemented as prismatic battery cells. In this example, the battery module 115C includes rows and columns of prismatic battery cells coupled together by an interconnect structure 200 (e.g., a collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together, and / or couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115C may include a charge collector or bus bar 202. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115C.

[0054] Figure 2B Also shown is a battery module 115D including prismatic battery cells and having an elongated shape, wherein the length of the battery module housing 223 (e.g., extending in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., a lateral direction along a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110). For example, one or more battery modules 115D having prismatic battery cells may span the entire front-to-back length of the battery pack within the battery pack frame 205. As shown, the battery module 115D may also include a bus bar 202 electrically coupled to the interconnect structure 200. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115D.

[0055] Another example: Figure 2B Also shown is a battery module 115E having a battery module housing 223 having a rectangular cube shape with a length approximately similar to the width and including a plurality of battery cells 120 implemented as pouch-shaped battery cells. In this example, the battery module 115C includes rows and columns of pouch-shaped battery cells coupled together by an interconnect structure 200 (e.g., a collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together and couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115E may include a charge collector or busbar 202. For example, the busbar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115E.

[0056] Figure 2BAlso shown is a battery module 115F including pouch-shaped battery cells and having an elongated shape, wherein the length of the battery module housing 223 (e.g., extending in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110) is substantially greater than the width of the battery module housing 223 (e.g., a lateral direction in a direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110). For example, one or more battery modules 115E having pouch-shaped battery cells may span the entire front-to-back length of the battery pack within the battery pack frame 205. As shown, the battery module 115E may also include a bus bar 202 electrically coupled to the interconnect structure 200. For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120, thereby providing a high voltage output from the battery module 115E.

[0057] In various implementations, the battery pack 110 may have any one or more of the battery modules 115A, 115B, 115C, 115D, 115E, and 115F. In one or more other implementations, the battery pack 110 may be provided without the battery modules 115 (eg, in a battery cell-pack implementation).

[0058] In one or more specific implementations, Figure 2B A plurality of battery modules 115 of any of the embodiments may be coupled (e.g., in series) to a current collector of the battery pack 110. In one or more embodiments, the current collector may be coupled to one or more external connectors (e.g., electrical contacts 203) on the battery pack 110 via a high voltage wiring harness. In one or more embodiments, a battery pack 110 may be provided without any battery modules 115. For example, the battery pack 110 may have a cell-to-cell configuration in which the battery cells 120 are arranged directly into the battery pack 110 without being assembled into modules 115 (e.g., without including a separate battery module housing 223). For example, the battery pack 110 (e.g., the battery pack frame 205) may include or define a plurality of structures for positioning the battery cells 120 directly within the battery pack frame 205.

[0059] Figure 2C A cross-sectional end view of a portion of a battery cell 120 is illustrated. Figure 2CAs shown, the battery cell 120 may include an anode 208, an electrolyte 210, and a cathode 212. As shown, the anode 208 may include or be electrically coupled to a first current collector 206 (e.g., a metal layer, such as a layer of copper foil or other metal foil). As shown, the cathode 212 may include or be electrically coupled to a second current collector 214 (e.g., a metal layer, such as a layer of aluminum foil or other metal foil). As shown, the battery cell 120 may include a first terminal 216 (e.g., a negative terminal) coupled to the anode 208 (e.g., via the first current collector 206) and a second terminal 218 (e.g., a positive terminal) coupled to the cathode (e.g., via the second current collector 214). In various specific implementations, the electrolyte 210 may be a liquid electrolyte layer or a solid electrolyte layer. In one or more specific implementations (e.g., an implementation in which the electrolyte 210 is a liquid electrolyte layer), the battery cell 120 may include a separator 220 that separates the anode 208 from the cathode 212. In one or more specific implementations in which the electrolyte 210 is a solid electrolyte layer, the solid electrolyte layer may serve as both a separator and an electrolyte layer.

[0060] In one or more specific implementations, the battery cell 120 may be implemented as a lithium-ion battery cell, wherein the anode 208 is formed of a carbonaceous material (e.g., graphite or silicon carbon). In these specific implementations, lithium ions may move from the anode 208 to the cathode 212 through the electrolyte 210 during the discharge of the battery cell 120 (e.g., and move from the cathode 212 to the anode 208 through the electrolyte 210 during the charging of the battery cell 120). For example, the anode 208 may be formed of a graphite material coated on a copper foil corresponding to the first current collector 206. In these lithium-ion specific implementations, the cathode 212 may be formed of one or more metal oxides (e.g., lithium cobalt oxide, lithium manganese oxide, lithium nickel manganese cobalt oxide (NMC), etc.) and / or lithium iron phosphate. As shown, the battery cell 120 may include a separator 220 that separates the anode 208 from the cathode 212. In the specific implementation in which the battery cell 120 is implemented as a lithium-ion battery cell, the electrolyte 210 may include a lithium salt in an organic solvent. The separator 220 may be formed of one or more insulating materials (e.g., polymers such as polyethylene, polypropylene, polyolefins, and / or polyamides, or other insulating materials such as rubber, glass, cellulose, etc.). The separator 220 may prevent contact between the anode 208 and the cathode 212, and may be permeable to the electrolyte 210 and / or ions within the electrolyte 210. In one or more specific implementations, the battery cell 120 may be implemented as a lithium polymer battery cell having a dry solid polymer electrolyte and / or a gel polymer electrolyte.

[0061] Although some examples are described herein in which the battery cells 120 are implemented as lithium-ion battery cells, some or all of the battery cells 120 in the battery module 115, battery pack 110, or other battery or battery device may be implemented using other battery cell technologies such as nickel metal hydride battery cells, lead acid battery cells, and / or supercapacitor cells. For example, in a nickel-metal hydride battery cell, the anode 208 may be formed of a hydrogen storage alloy, and the cathode 212 may be formed of nickel oxide-hydride. In the example of a nickel-metal hydride battery cell, in one or more examples, the electrolyte 210 may be formed of an aqueous potassium hydroxide solution.

[0062] In one or more other specific implementations, the battery cell 120 may be implemented as a lithium-sulfur battery cell. For example, in a lithium-sulfur battery cell, the anode 208 may be at least partially formed of lithium, the cathode 212 may be at least partially formed of sulfur, and the electrolyte 210 may be formed of a cyclic ether, a short-chain ether, a glycol ether, an ionic liquid, a supersaturated salt-solvent mixture, a polymer gel organic medium, a solid polymer, a solid inorganic glass, and / or other suitable electrolyte materials.

[0063] In various specific implementations, Figure 2C The anode 208, electrolyte 210, and cathode 212 are packaged into a battery cell housing having any of a variety of shapes and / or sizes and / or formed from any of a variety of suitable materials. For example, the battery cell 120 may have an outer shape that is cylindrical, rectangular, square, cubic, flat, pouch-shaped, elongated, or prismatic. Figure 2D As depicted, for example, a battery cell such as battery cell 120 may be implemented as a cylindrical core. Figure 2D In the example of , the battery cell 120 includes a cell housing 215 having a cylindrical outer shape. For example, the anode 208, the electrolyte 210, and the cathode 212 can be wound into one or more substantially cylindrical windings 221. As shown, one or more windings 221 of the anode 208, the electrolyte 210, and the cathode 212 (e.g., and / or one or more separator layers, such as separator layer 220) can be disposed within the cell housing 215. For example, a separator layer can be disposed between adjacent windings 221. However, Figure 2D The cylindrical cell implementation of is merely exemplary, and other implementations of the battery cell 120 are contemplated.

[0064] For example, Figure 2E An example is illustrated in which the battery cell 120 is implemented as a prismatic cell. Figure 2EAs shown, the battery cell 120 may include a cell housing 215 having a right prism-like outer shape. As shown, one or more layers of an anode 208, a cathode 212, and an electrolyte 210 disposed therebetween may be disposed (e.g., with a separator material between each layer) within a cell housing 215 having a right prism-like shape. For example, multiple layers of an anode 208, an electrolyte 210, and a cathode 212 may be stacked (e.g., with a separator material between each layer), or a single layer of an anode 208, an electrolyte 210, and a cathode 212 may be formed into a flat spiral shape and provided in a cell housing 215 having a right prism-like shape. Figure 2E In a specific implementation, the unit housing 215 has a relatively thick cross-sectional width 217 and is formed of a rigid material. For example, Figure 2E The unit housing 215 in a specific implementation may be formed from a welded, stamped, deep drawn and / or impact extruded metal sheet such as a welded, stamped, deep drawn and / or impact extruded aluminum sheet. For example, Figure 2E The cross-sectional width 217 of the cell housing 215 may be up to or greater than 1 millimeter (mm) to provide a rigid housing for the prismatic battery cell. In one or more specific implementations, Figure 2E The first terminal 216 and the second terminal 218 in the prismatic unit embodiment may be formed by a feed-through conductor, which is formed by the conductor passing through the unit housing 215 to expose the first terminal 216 and the second terminal 218 to the outside of the unit housing 215 (for example, for use with Figure 2B However, Figure 2E This implementation of is also exemplary, and yet other implementations of the battery cell 120 are contemplated.

[0065] For example, Figure 2F An example is illustrated in which the battery cell 120 is implemented as a pouch-shaped cell. Figure 2F As shown, one or more layers of anode 208, cathode 212, and electrolyte 210 disposed therebetween may be disposed (e.g., with separator material between the layers) within a cell housing 215 that forms a flexible or stretchable pouch-like housing. Figure 2F In a specific implementation, the unit housing 215 has a relatively thin cross-sectional width 219. For example, Figure 2F The unit housing 215 in a specific implementation may be formed of a flexible or ductile material (e.g., a foil, such as a metal foil, or a film, such as an aluminum-coated plastic film). Figure 2F The cross-sectional width 219 of the cell housing 215 can be as low as or less than 0.1 mm, 0.05 mm, 0.02 mm, or 0.01 mm to provide a flexible or stretchable housing for the pouch-shaped battery cell. In one or more specific implementations, Figure 2FThe first terminal 216 and the second terminal 218 in the pouch cell embodiments of the present invention may be formed by conductive tabs (e.g., foil tabs) that are coupled (e.g., welded) to the anode 208 and cathode 212, respectively, and sealed to the pouch that forms the cell housing 215 in these embodiments. Figure 2C , Figure 2E and Figure 2F In the example of FIG. 1 , the first terminal 216 and the second terminal 218 are formed on the same side (e.g., the top side) of the battery cell 120. However, this is merely illustrative, and in other specific implementations, the first terminal 216 and the second terminal 218 may be formed on two different sides (e.g., opposite sides, such as the top side and the bottom side) of the battery cell 120. In various specific implementations, the first terminal 216 and the second terminal 218 may be formed on Figure 2D on the same side or different sides of the cylindrical unit.

[0066] In one or more specific implementations, the battery module 115, the battery pack 110, the battery cells, or any other battery or battery subassembly may include some battery cells 120 implemented as solid-state battery cells and other battery cells 120 implemented with liquid electrolytes for lithium ions or other battery cells with liquid electrolytes. One or more of the battery cells 120 may be included in the battery module 115 or the battery pack 110 to provide a power supply for a component of the vehicle 100, a building 180, or any other electric component or device. The cell housing 215 of the battery cell 120 may be disposed in the battery module 115, disposed in the battery pack 110, or installed in any of the vehicle 100, the building 180, or any other electric component or device.

[0067] Figure 3 A perspective view of a battery module according to one or more implementations is illustrated. Figure 3 In the example of , the battery module 115 includes a top submodule 304 and a bottom submodule 306. As shown, each of the top submodule 304 and the bottom submodule 306 may include a cell carrier 310. In one or more specific implementations, each cell carrier 310 may be a single-piece, unitary body (e.g., a molded body formed of plastic and / or other materials) and may include structural features 311 along its sidewalls. These structural features 311 may enhance the strength of the sidewalls of the carrier and thereby reduce or eliminate the need for additional structural reinforcement components of the battery module 115, such as shear walls attached to the cell carrier 310. Figure 3 Also visible in FIG. 3 is a cold plate 308 disposed between the top submodule 304 and the bottom submodule 306. The cold plate 308 may be connected to the battery cells in the top submodule 304 (in Figure 3 ) and the battery cells in the bottom submodule 306 (not visible in Figure 3) to provide thermal control for both the top submodule 304 and the bottom submodule 306.

[0068] Figure 3 Also illustrated is a cover 314 that may be disposed on the top and / or bottom of the battery module 115 . Figure 3 Also illustrated is a balanced voltage and temperature (BVT) module 316 to which a plurality of thermistor assemblies 318 are communicatively coupled. The BVT may be a modular assembly of various electrical components to monitor or control components of a battery subassembly. For example, the BVT may include a circuit board attached to a housing of the BVT. The BVT may have various connectors to couple with, for example, a thermistor that can measure the temperature of a battery subassembly, a battery module, and / or its battery cells, a voltage sensor or balancer that can sense or control the voltage flowing through a battery subassembly, a battery module, and / or its battery cells, or a communication device that can receive, transmit, or analyze data associated with a battery subassembly, a battery module, and / or its battery cells. Figure 3 Also illustrated are a bus bar 320 (e.g., a positive bus bar) electrically coupled to a first terminal (e.g., a positive terminal) of the battery cells of the top submodule 304 and the bottom submodule 306 and a bus bar 322 (e.g., a negative bus bar) electrically coupled to a second terminal (e.g., a negative terminal) of the battery cells of the top submodule 304 and the bottom submodule 306.

[0069] Figure 4 Illustrated Figure 3 1, wherein the battery cells 120 of the top submodule 304 and the battery cells 120 of the bottom submodule 306 can be seen. In one or more examples described herein, the battery modules 115, Figure 3 and / or Figure 4 A subset of the components of the battery module 115 shown (e.g., the top submodule 306, the bottom submodule 306, and / or another subset of the components of the battery module) or any other grouping of battery cells (e.g., including a battery pack having multiple battery modules and / or other battery subassemblies) may be referred to as a battery subassembly.

[0070] exist Figure 4 In the example of FIG. 1 , two current collector assemblies (CCAs) 400 can also be seen, which connect the terminals of the battery cells 120 of the top submodule 304 and the bottom submodule 306 to the busbars 320 and 322 when the battery module 115 is assembled. Figure 4As shown, a series bus bar 406 may also be provided (e.g., on an end of the unit carrier 310 opposite the end of the unit carrier where the bus bars 320 and the bus bars 322 are mounted). For example, the series bus bar 406 may electrically couple the battery cells 120 of the top submodule 304 to the battery cells 120 of the bottom submodule 306. As shown, a cover 314 may be provided for the top submodule 304, and a cover 314 may be provided for the bottom submodule 306.

[0071] As discussed in further detail below, the battery cells 120 of the top submodule 304 may be inserted into a crate structure formed by the cell carrier 310 of the top submodule 304, and the battery cells 120 of the bottom submodule 306 may be inserted into a crate structure formed by the cell carrier 310 of the bottom submodule 306. Figure 3 and Figure 4 As shown, the orientation of the cell carrier 310 and battery cells 120 of the top submodule 304 can be substantially opposite (e.g., upside down relative to the orientation of the cell carrier 310 and battery cells 120 of the bottom submodule 306). In this way, the single cold plate 308 can be in thermal contact with the same end (e.g., the bottom end) of the battery cells 120 of both the top submodule and the bottom submodule and provide substantially symmetrical thermal contact with the top submodule and the bottom submodule.

[0072] Figure 5 A top perspective view of a thermal component (eg, a cold plate) of a battery module according to one or more implementations is illustrated. Figure 5 As shown, the cold plate 308 may include a plate assembly 1200. The plate assembly 1200 may include a flange 1204 along one or more edges thereof. In one or more specific implementations, one or more positioning features 1206 (e.g., for the unit carrier 310) and / or one or more positioning (e.g., datuming) features 1208 may be formed along the flange 1204. In one or more specific implementations, a thermally conductive material 1202 (e.g., a thermally conductive adhesive) may be formed on a substantially planar outer surface of the plate assembly 1200. In one or more other specific implementations, the thermally conductive adhesive may be a multi-component acrylic paste. Figure 5 In the example of FIG. 3 , it can be seen that the thermally conductive material 1202 is on one side of the cold plate 308 for thermally coupling to the battery cells 120 of the first submodule (the bottom submodule 306). In one or more specific implementations, the thermally conductive material 1202 can also be disposed on the cold plate 308. Figure 5 On the other side, which is not visible in FIG. 1 , for thermal coupling to the battery cells 120 of the second submodule (top submodule 304 ).

[0073] Figure 6A top view of a portion of a thermal component (eg, a cold plate) of a battery module according to one or more implementations is illustrated. For example, Figure 6 The example has a top plate, a bottom plate (in Fig.13 Not visible in, see e.g. Fig.14 ) and an intermediate plate 1350 of the plate assembly 1200 disposed between the top plate and the bottom plate. Figure 6 As shown, in one or more specific implementations, the intermediate plate 1350 may define a serpentine flow path 1300 for a fluid (e.g., a hot fluid, such as a coolant fluid or a warming fluid) from an inlet port 1302 to an outlet port 1304. For example, the serpentine flow path 1300 may define a plane and / or be defined within a plane. For example, the cold plate 308 may include one or more structural features 1307 that extend across (e.g., through) the serpentine flow path (e.g., across or through the plane). For example, the structural features 1307 may increase the burst pressure threshold of the cold plate. The structural features 1307 may prevent the cold plate from being compressed by an external force and / or may prevent the cold plate from expanding due to fluid pressure within the cold plate.

[0074] The structural features 1307 can separate some portions of the serpentine flow path 1300 from some other portions of the serpentine flow path 1300. For example, a plurality of structural features 1307 can separate a plurality of sub-channels 1306 that are partially defined by the structural features 1307. As shown, the sub-channels 1306 can be formed on the first side 1303 of the intermediate plate 1350 (e.g., at the bottom of the intermediate plate 1350). Figure 6 1300). As shown, multiple sub-channels 1306 can be combined to form each of several segments of the serpentine flow path 1300. For example, these segments may include linear segments extending between turns or corners of the serpentine flow path 1300.

[0075] In one or more specific implementations, the subchannels 1306 within each segment of the serpentine flow path 1300 can be separated from each other by structural features 1307 along the length of the segment, and can be fluidically coupled together at or near the end of each segment. As shown, each segment of the serpentine flow path 1300 (e.g., each segment includes multiple subchannels 1306) can be fluidly separated from adjacent parallel segments of the serpentine flow path 1300 by a fluid barrier 1330 that at least partially defines the serpentine flow path 1300.

[0076] In one or more specific implementations, the structural features 1307 can each extend from the floor of the corresponding subchannel 1306 to the corresponding ridge 1309. Figure 7 ) discussed in further detail, each ridge 1309 may be on an opposite second side of the plate (at Figure 6As shown, the structural feature 1307 may include a structural feature formed into segments, the segments including a first segment extending from the inlet port 1302 to a first center portion of the intermediate plate 1350, a segment extending perpendicularly to the first segment from the first center portion to a second center portion of the intermediate plate 1350, a third segment extending perpendicularly to the first segment and parallel to the first segment from the second center portion to a first edge portion of the intermediate plate 1350, a fourth segment extending perpendicularly to the third segment from the first edge portion to a first corner of the intermediate plate 1350, a fifth segment extending perpendicularly to the fourth segment and parallel to the third segment from the first corner of the intermediate plate 1350 to the second corner of the intermediate plate 1350, a sixth segment extending perpendicularly to the fifth segment from the second corner to the third corner of the intermediate plate 1350, and a seventh segment extending perpendicularly to the sixth segment from the third corner of the intermediate plate 1350 to the outlet port 1304. Figure 6 As shown, the middle plate 1350 may include one or more openings 1308. As shown, the first, second, third, fourth, fifth, sixth, and seventh segments of the structural feature 1307 may be separated from each other by gaps, and one or more of the openings 1308 are formed at the gaps. The openings 1308 may be configured to allow cooling fluid to flow through the middle plate 1350 (e.g., between the serpentine flow path 1300 on a first side of the plate and an additional serpentine flow path on an opposite second side of the middle plate 1350). In this way, the cooling fluid flowing through the serpentine flow path 1300 may traverse the opposite side of the middle plate 1350, and vice versa. In one or more specific implementations, the openings 1308 may be configured (e.g., sized, shaped, and / or positioned) to generate turbulence in the flow of fluid through the serpentine flow path 1300. For example, turbulence may increase the efficiency of heat transfer of the fluid (e.g., to the top plate and the bottom plate).

[0077] like Figure 6 As shown, a first group of openings 1311 of openings 1308 may be arranged in a first row that extends diagonally from a first corner of the cold plate away from a first edge and a second edge of the cold plate that defines the first corner. For example, the first group of openings 1311 of openings 1308 may be located at a turn (e.g., a corner) in the serpentine flow path 1300 (e.g., to increase the amount of mixing across the middle plate 1350 and / or to increase the amount of turbulence in the cooling fluid flowing through the serpentine flow path 1300). As shown, a second group of openings 1313 of openings 1308 may be arranged in a second row that extends diagonally from a second corner of the cold plate toward an inner end of the first row and away from a second edge and a third edge of the cold plate that defines the second corner (e.g., at another turn or corner in the serpentine flow path 1300).

[0078] As shown, a third group of openings 1315 of the openings 1308 can be arranged in a third row that extends diagonally from a third corner of the cold plate away from a third edge and a fourth edge of the cold plate that define the third corner (e.g., at another turn or corner in the serpentine flow path 1300). As shown, a fourth group of openings 1317 of the openings 1308 can be arranged in a fourth row that extends from a location along the fourth edge of the cold plate toward an inner end of the third row (e.g., at another turn or corner in the serpentine flow path 1300). In one or more specific implementations, the middle plate 1350 can include one or more openings 1308 (e.g., one or more rows of openings 1308) at each corner or turn of the serpentine flow path 1300. In one or more specific implementations, the middle plate 1350 can include a row of openings 1308 at the beginning of each linear segment of the serpentine flow path 1300 and a row of openings 1308 at the end of each linear segment of the serpentine flow path 1300. In one or more implementations, a row of openings 1308 at the beginning of each linear segment of the serpentine flow path 1300 may be parallel to a row of openings 1308 at the end of the next linear segment of the serpentine flow path 1300 (e.g., such that each row of openings 1308 forms a row of parallel opening pairs). Figure 6 In the example of FIG. 1 , each of the openings 1308 forms a slot (eg, an elongated narrow opening) in the middle plate 1350. In one or more other implementations, one or more of the openings 1308 may have a Figure 6 The slot shape shown is different from one or more other shapes.

[0079] exist Figure 6 In the example of , the serpentine flow path 1300 includes four sub-channels 1306 (e.g., separated by three ridges 1309), each of which traverses the entire serpentine flow path 1300 and is fluidically coupled together at each turn or corner of the serpentine flow path 1300 (e.g., at the end of each linear segment). However, this is merely exemplary, and in other specific implementations, the serpentine flow path 1300 may include fewer or more than four sub-channels 1306 (e.g., separated by fewer or more than three ridges 1309), each of which traverses some or all of the entire serpentine flow path 1300 and may be fluidly separated or fluidly coupled together at one or more turns or corners or other locations along the serpentine flow path 1300.

[0080] As shown, the openings 1308 may include openings 1308 located away from the inlet port 1302 and the outlet port 1304, and may include a fifth group of openings 1351 of openings 1308 at or near the inlet port 1302. For example, by providing the openings 1308 at or near the inlet port 1302, a portion of the cooling fluid introduced into the cold plate 308 via the inlet port 1302 on a first side of the middle plate 1350 may immediately traverse (e.g., through the openings 1308 at or near the inlet port 1302) to the other side of the middle plate 1350. In this way, the opening 1308 at or near the inlet port 1302 can facilitate the simultaneous initiation of the flow of the cooling fluid (e.g., upon introduction into the cold plate 308 via the inlet port 1302 and before the cooling fluid travels to the end of the serpentine flow path 1300 on the first side of the plate) through a first serpentine flow path (e.g., serpentine flow path 1300) on the first side 1303 of the middle plate 1350 and a second serpentine flow path (e.g., a second serpentine flow path that is a mirror image of the serpentine flow path 1300) on the opposite second side of the middle plate 1350. In this way, the thermal control provided by the cold plate 308 can be provided to the battery cells 120 on both sides of the cold plate 308 (e.g., in the top submodule 304 and the bottom submodule 306) more quickly and therefore more efficiently, which can facilitate more efficient and / or more reliable power delivery from the battery cells 120. As shown, intermediate plate 1350 may also include a sixth set 1353 of openings 1308 at or near outlet port 1304 .

[0081] Figure 7 A cross-sectional side view of a cold plate 308 is illustrated according to one or more implementations. Figure 7 As shown in FIG. 1 , in one or more specific implementations, the cold plate 308 may be formed by a top plate 700, a bottom plate 702, and an intermediate plate 1350 disposed between the top plate 700 and the bottom plate 702. As shown, the subchannel 1306 is formed on the first side 1303 of the intermediate plate 1350. Figure 7 As shown, one or more of the structural features 1307 may each extend from the bottom surface of the corresponding sub-channel 1306 to a respective ridge 1309 . Figure 7 Also shown is how each ridge 1309 (eg, opposite sides of each ridge 1309 ) forms additional sub-channels 704 for additional serpentine flow paths on the opposite second side 712 of the intermediate plate 1350 . Figure 7 Also shown is how the bottom surface of each subchannel 1306 on the first side 1303 of the intermediate plate 1350 may correspond to the ridge 706 on the opposite second side 712 of the intermediate plate 1350. For example, the structural feature 1307 may be formed by undulations in the intermediate plate 1350. For example, Figure 7, each of the plurality of undulations in the middle plate 1350 may be used for a corresponding one of the structural features 1307, which may include a corresponding ridge 1309, a corresponding ridge 706, and a portion of the middle plate 1350 extending from the corresponding ridge 1309 and the corresponding ridge 706 through the serpentine flow path 1300. In one or more implementations, the ridge 1309 may be attached (e.g., brazed or welded) to the top plate 700. These brazes and / or welds may separate the subchannels 1306 from each other. In one or more implementations, the ridges 706 on the opposite second side 712 of the middle plate 1350 may be attached (e.g., brazed or welded) to the bottom plate 702. These brazes and / or welds may separate the subchannels 704 from each other.

[0082] like Figure 7 As illustrated in the example of , the cold plate 308 may include a plurality of structural features 1307 formed by undulations in the middle plate 1350 and each extending from the bottom surface of the corresponding sub-channel 1306 to a corresponding ridge 1309. As shown, each of the structural features 1307 may include a corresponding one of the ridges 1309, and each ridge 1309 may form an additional sub-channel 704 of an additional serpentine flow path on the opposite second side 712 of the middle plate 1350.

[0083] Figure 8 A perspective view of a portion of the middle plate 1350 near some of the openings 1308 is illustrated. As shown, in one or more implementations, one or more openings 1308 can be formed at the end 802 of one or more ridges 1309. Figure 8 Also illustrated is how two or more subchannels 1306 may be fluidly coupled together at or near the ends 802 of a ridge 1309 (eg, along a portion 804 of the intermediate plate extending between the ends of the subchannels in a direction substantially perpendicular to the subchannels). Fig. 9 A cross-sectional perspective view of a portion of the cold plate 308 is illustrated, showing how the flange 1204 may be formed by an end portion of the middle plate 1350 that is between and in contact with (e.g., attached to, such as welded to) the corresponding ends of the top plate 700 and the bottom plate 702. As shown, the features of the flange (such as Figure 5 The locating features 1206 and / or the locating features 1208 may be formed in (eg, extend through) the top plate 700 , the middle plate 1350 , and the bottom plate 702 .

[0084] Fig.10 A side view of a portion of a cold plate 308 attached to a battery cell 120 is illustrated according to one or more implementations. For example, the thermally conductive material 1202 may include an adhesive that attaches the bottom end of the battery cell 120 to the cold plate 308. Fig.12In an example of , the battery cell 120 can be the outermost battery cell of a group of battery cells (e.g., in a battery subassembly, such as the top submodule 304 or the bottom submodule 306 described herein). As shown, the battery cells 120 (e.g., the bottom surfaces of the battery cells 120) can each be disposed within the outer boundary 1000 of the thermal contact surface 1002 of the cold plate 308 (e.g., the outer edge of the outermost battery cell 120 can be substantially aligned with the outer boundary 1000 of the thermal contact surface 1002). For example, the thermal contact surface 1002 can be the outer surface of a thermally conductive material 1202 (e.g., a thermally conductive adhesive). In this way, the entire bottom surface of each battery cell 120 can be in thermal contact with the cold plate 308 (e.g., with the thermally conductive material 1202), which can prevent or avoid reduced thermal control of the outer rows / columns of battery cells 120 in the battery subassembly.

[0085] Fig.11 A perspective bottom view of a partially assembled battery module 115 having a cold plate 308 with a locating feature 1206 is illustrated according to one or more implementations. As shown, the locating feature 1206 may include an opening that receives a pin 1101 or other protrusion on a cell carrier 310 (e.g., a cell carrier 310 of a top submodule 304 or a bottom submodule 306 as described herein). Fig.11 In the example of FIG. 3 , the pin 1101 of the unit carrier 310 is received in the inner locating feature 1206 of the two locating features 1206 . Fig.11 Not shown, but related to Fig.11 Another unit carrier 310 (e.g., a unit carrier 310 of the other of the top submodule 304 or the bottom submodule 306 described herein) that is oriented opposite to the orientation of the unit carrier 310 shown in FIG. 1 may have locating pins that are received in the outer locating features 1206. In this way, the locating features 1206 of the cold plate 308 may be used to locate the top submodule 304 and the bottom submodule 306 of the battery module 115 to the cold plate 308.

[0086] Fig.12A top view of a cold plate 308 is illustrated showing how positioning features 1208 (e.g., datuming features) may be used to position the cold plate 308 (and / or the battery modules 115 or other battery subassemblies within which the cold plate 308 is disposed) relative to one or more battery pack structures. For example, positioning features 1208 (e.g., datuming features) may be used to position the cold plate 308 (and / or the battery modules 115 or other battery subassemblies within which the cold plate 308 is disposed) relative to a cross member 1251 extending between battery modules 115 within a battery pack 110. As shown, the positioning features 1208 may include openings or recesses that allow positioning equipment (e.g., a camera or other sensor of positioning equipment that may lift and / or move the cold plate 308 and / or the battery modules 115 within which the cold plate 308 is disposed) to view one or more positioning features 1250 on the cross member 1100 or another battery pack structure. For example, positioning equipment including a camera or other sensor can lift and lower a battery module 115 including a cold plate 308 and can track the position of the positioning feature 1250 relative to the positioning feature 1208 while placing the battery module including the cold plate 308 in an appropriate position relative to the cross member 1251 (e.g., for attachment to the cross member 1251 and / or other battery pack structures).

[0087] For example Figure 5 , Fig. 9 , Fig.11 and Fig.12 As illustrated, in one or more implementations, the cold plate 308 includes a flange 1204 extending along an edge of the cold plate 308 outside the serpentine flow path 1300. The flange may include one or more locating features 1206 for attaching the cold plate to one or more cell carriers 310 of the battery module 115. In one or more implementations (e.g., Figure 3 and Figure 4 ), the cold plate 308 may be disposed between two groups of battery cells, such as between a pair of battery modules (eg, the top module 304 and the bottom module 306 of the battery module 115) in an electric vehicle (eg, the vehicle 100). Fig.13 A top view of a portion of the cold plate 308 is illustrated, showing how the openings 1308 can be separated by gaps 1310 and gaps 1380 in one or more implementations.

[0088] Fig.14 A flow chart illustrating an exemplary process 1400 that may be performed to provide thermal control using a cold plate according to an implementation of the subject technology. Figures 5 to 13 The process 1400 is described with reference to the cold plate 308. However, the process 1400 is not limited to Figures 5 to 13The cold plate 308 of process 1400, and one or more blocks (or operations) of process 1400 may be performed by one or more other structural components of other suitable devices, equipment or systems. Further for the purpose of explanation, some blocks of process 1400 are described herein as occurring continuously or linearly. However, multiple blocks of process 1400 may occur in parallel. In addition, the blocks of process 1400 do not need to be performed in the order shown, and / or one or more blocks of process 1400 do not need to be performed and / or may be replaced by other operations.

[0089] like Fig.14 , at block 1402, a fluid (e.g., a cooling fluid) may be provided to a cold plate (e.g., the cold plate 308) on a first side (e.g., the first side 1303) of a middle plate (e.g., the middle plate 1350) of the cold plate. For example, the fluid may be provided to a cavity within the cold plate (e.g., a cavity between the top plate 700 and the bottom plate 702, the middle plate 1350 being disposed within the cavity to define one or more flow paths and / or to separate a top portion and a bottom portion of the cavity) via the inlet port 1302.

[0090] At block 1404, simultaneous initiation of fluid flow may be facilitated through a first serpentine flow path (e.g., serpentine flow path 1300) on a first side of the middle plate and a second serpentine flow path (e.g., a second serpentine flow path that is a mirror image of serpentine flow path 1300 and includes subchannels 704 defined by ridges 1309, ridges 706, and / or structural features 1307) on an opposing second side of the middle plate (e.g., opposing second side 712). For example, facilitating simultaneous initiation of flow may include allowing fluid to flow from the first side of the middle plate to the opposing second side of the middle plate through one or more openings (e.g., openings 1308, such as fifth group 1351 of openings 1308) in the middle plate that are located at or near an inlet port (e.g., inlet port 1302) of the cold plate.

[0091] In one or more specific implementations, process 1400 may also include allowing fluid to flow from a first side of the intermediate plate to an opposite second side of the intermediate plate or from an opposite second side of the intermediate plate to a first side of the intermediate plate through one or more additional openings (e.g., first group of openings 1311, second group of openings 1313, third group of openings 1315, fourth group of openings 1317, and / or one or more other openings 1308 or a collection of openings 1308) in the intermediate plate at turns or corners in the first serpentine flow path (e.g., and the second serpentine flow path). In one or more specific implementations, process 1400 may also include providing thermal control (e.g., cooling) to the one or more battery cells via thermal coupling between the cold plate and the one or more battery cells (e.g., two groups of battery cells in contact with two opposite sides of the cold plate). In one or more specific implementations, process 1400 may also include operating an electric vehicle using the one or more battery cells.

[0092] Aspects of the subject technology can help improve the efficiency and / or reliability of battery cells, which can help improve the efficiency and / or range of electric vehicles. This can help promote the operation and / or popularity of electric vehicles, which can have a positive impact on the climate by reducing greenhouse gas emissions.

[0093] Unless otherwise specified, an element mentioned in the singular is not intended to represent one and only one, but one or more. For example, "a" module may refer to one or more modules. In the absence of further constraints, an element beginning with "a", "an", "the" or "said" does not exclude the presence of other identical elements.

[0094] Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the terms "including" or "having" and the like are used, such terms are intended to be inclusive in a manner similar to the term "comprising" as understood when "including" is used as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0095] Phrases such as an aspect, this aspect, another aspect, some aspects, one or more aspects, a specific implementation, this specific implementation, another specific implementation, some specific implementations, one or more specific implementations, an embodiment, this embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, this configuration, another configuration, some configurations, one or more configurations, subject technology, this disclosure, the present disclosure, other variations thereof, etc. are for convenience and do not imply that the disclosures associated with such phrases are necessary for the subject technology, or that such disclosures are applicable to all configurations of the subject technology. The disclosures associated with such phrases may be applicable to all configurations or one or more configurations. The disclosures associated with such phrases may provide one or more examples. Phrases such as an aspect or some aspects may refer to one or more aspects, and vice versa, and this is similarly applicable to other aforementioned phrases.

[0096] The phrase "at least one" preceding a list of items, with the terms "and" or "or" used to separate any of those items, modifies the list as a whole, rather than as each constituent item of the list. The phrase "at least one" does not require selection of at least one item; rather, the phrase allows for a meaning that includes at least one of any of those items, and / or at least one of any combination of those items, and / or at least one of each of those items. As an example, each of the phrases "at least one of A, B, and C" or "at least one of A, B, or C" means only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0097] It should be understood that the specific order or level of the disclosed steps, operations or processes is an illustration of an exemplary method. Unless otherwise clearly stated, it should be understood that the specific order or level of steps, operations or processes can be performed in different orders. Some of the steps, operations or processes can be performed simultaneously. The attached method claims (if any) present the elements of various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or level presented. These can be performed continuously, linearly, in parallel or in different orders. It should be understood that the instructions, operations and systems described can usually be integrated together in a single software / hardware product or packaged into multiple software / hardware products.

[0098] In one aspect, the term "coupled" or the like may refer to a direct coupling. In another aspect, the term "coupled" or the like may refer to an indirect coupling.

[0099] Terms such as top, bottom, front, back, side, horizontal, vertical, etc. refer to an arbitrary reference frame, not the ordinary gravitational reference frame. Thus, such terms may extend upward, downward, diagonally, or horizontally in a gravitational reference frame.

[0100] The present disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are shown in block diagram form to avoid confusion with the various concepts of the subject technology. The present disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Those skilled in the art will readily appreciate various modifications to these aspects, and the principles described herein may be applied to other aspects.

[0101] All structural and functional equivalents of the various elements of the various aspects described throughout this disclosure are known or will later become known to those of ordinary skill in the art, and these equivalents are expressly incorporated herein by reference and are intended to be included in the claims. In addition, nothing disclosed herein is intended to serve the public, regardless of whether such disclosure is explicitly stated in the claims. No claim element should be interpreted under the provisions of 35 USC § 112 (f) unless the element is explicitly stated using the phrase "means for..." or, in the case of a method claim, the element is stated using the phrase "step for..."

[0102] Those skilled in the art will appreciate that the various illustrative frames, modules, elements, parts, methods and algorithms described herein can be implemented as hardware, electronic hardware, computer software or a combination thereof. In order to illustrate this interchangeability of hardware and software, various illustrative frames, modules, elements, parts, methods and algorithms have been generally described above in terms of their functionality. Whether this functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the entire system. Those skilled in the art can implement the described functionality in different ways for each specific application. Various parts and frames can be arranged differently (e.g., arranged in different orders or divided in different ways), all of which do not depart from the scope of this subject technology.

[0103] The invention title, background technology, figure description, abstract of the specification, and drawings are hereby incorporated into the present disclosure and are provided as illustrative examples of the present disclosure rather than as limiting descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that for the purpose of simplifying the present disclosure, the description provides illustrative examples and various features are grouped together in various specific implementations. The method of the present disclosure should not be interpreted as reflecting the intention that the claimed subject matter requires more features than those explicitly stated in each claim. On the contrary, as reflected in the claims, the inventive subject matter lies in less than all the features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim independently serving as a separately claimed subject matter.

[0104] The claims are not intended to be limited to the aspects described herein, but should be given the full scope consistent with the language of the claims and encompassing all legal equivalents. Nevertheless, none of the claims is intended to encompass subject matter that fails to satisfy the requirements of applicable patent law, nor should it be interpreted in such a manner.

Claims

1. A device comprising: A plate includes a serpentine flow path for a thermal fluid from an inlet port to an outlet port, wherein the plate includes a plurality of structural features extending across the serpentine flow path. 2 . The apparatus of claim 1 , wherein the plurality of structural features increase a burst pressure threshold of the cold plate.

3. The device of claim 1, wherein the plurality of structural features separate a plurality of sub-channels of the serpentine flow path, and wherein the sub-channels are defined in part by the plurality of structural features and define the serpentine flow path on the first side of the plate.

4. The device of claim 1, wherein the plurality of structural features are formed by undulations in the plate, and each structural feature extends from a floor of a corresponding subchannel to a respective ridge.

5. The device of claim 4, wherein each of the structural features comprises a respective one of the ridges, and wherein each ridge forms an additional sub-channel of an additional serpentine flow path on an opposing second side of the plate.

6. The apparatus of claim 1, wherein the plate further comprises a plurality of openings that allow the thermal fluid to flow through the plate between the serpentine flow path on a first side of the plate and an additional serpentine flow path on an opposing second side of the plate.

7. The device according to claim 6, wherein: a first group of the plurality of openings arranged in a first row, the first row extending diagonally from a first corner of the panel away from a first edge and a second edge of the panel defining the first corner; a second group of openings of the plurality of openings arranged in a second row extending diagonally from a second corner of the panel toward an inner end of the first row and away from the second edge and a third edge of the panel defining the second corner; a third group of the plurality of openings being arranged in a third row extending diagonally from a third corner of the panel away from the third and fourth edges of the panel defining the third corner; and A fourth group of openings of the plurality of openings is arranged in a fourth row extending from a location along the fourth edge of the plate toward an inner end of the third row.

8. The device of claim 1, wherein the plate further comprises a plurality of openings located at one or more corners in the serpentine flow path.

9. The apparatus of claim 1, wherein the plate comprises a middle plate of a cold plate, the cold plate being formed by a top plate, a bottom plate, and the middle plate disposed between the top plate and the bottom plate.

10. The apparatus of claim 9, wherein the cold plate further comprises a flange extending along an edge of the cold plate outside of the serpentine flow path, and wherein the flange comprises one or more locating features for attaching the cold plate to one or more unit carriers.

11. The apparatus of claim 10, wherein the flange further comprises one or more datuming features configured to facilitate alignment of the battery module with one or more structures of a battery pack.

12. The apparatus of claim 9, further comprising a plurality of battery cells, each battery cell disposed within an outer boundary of the thermal contact surface of the cold plate.

13. The device of claim 1, wherein the plate is disposed between two groups of battery cells in an electric vehicle.

14. The apparatus of claim 1 , wherein the plurality of structural features comprises a structural feature formed into a segment, the segment comprising: a first segment extending from the inlet port to a first central portion of the plate, and a second segment extending perpendicularly to the first segment from the first central portion to a second central portion of the plate; a third segment extending perpendicularly to the first segment and parallel to the first segment from the second central portion to a first edge portion of the plate, and a fourth segment extending perpendicularly to the third segment from the first edge portion to a first corner of the plate; a fifth segment extending from the first corner of the plate to the second corner of the plate perpendicular to the fourth segment and parallel to the third segment, a sixth segment extending from the second corner of the plate to the third corner perpendicular to the fifth segment, and a seventh segment extending from the third corner of the plate to the outlet port perpendicular to the sixth segment.

15. A thermal component comprising: An intermediate plate defines a serpentine flow path for a cooling fluid from the inlet port to the outlet port, wherein the intermediate plate includes a plurality of structural features extending across the serpentine flow path.

16. The thermal component of claim 15, wherein the plurality of structural features are formed by a plurality of corresponding undulations in the intermediate plate.

17. The thermal component of claim 15, wherein each of the plurality of structural features comprises a ridge defining a portion of an additional serpentine flow path on an opposing second side of the intermediate plate.

18. A method comprising: providing a fluid into the cold plate on a first side of a middle plate of the cold plate; as well as Simultaneous initiation of the fluid flow through a first serpentine flow path on a first side of the intermediate plate and a second serpentine flow path on an opposing second side of the intermediate plate is facilitated.

19. The method of claim 18, wherein facilitating the simultaneous initiation of the flows comprises allowing the fluid to flow from the first side of the middle plate to the opposing second side of the middle plate through one or more openings in the middle plate located at or near an inlet port of the cold plate.

20. The method of claim 18, further comprising allowing the fluid to flow from the first side of the intermediate plate to the opposite second side of the intermediate plate or from the opposite second side of the intermediate plate to the first side of the intermediate plate through one or more openings in the intermediate plate located at a turn in the first serpentine flow path.

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