Battery pack with integrated cooling system

Abstract

The battery pack includes a first header having a first conduit and a second header having a second conduit. The battery pack also includes an energy storage system having energy storage cells disposed between the first header and the second header. A coolant plate assembly is disposed between the first header and the second header and adjoins the plurality of energy storage cells. The coolant plate assembly includes a coolant channel having a first end fluidly connected to the first conduit, a second end fluidly connected to the second conduit, and an intermediate portion defining a flow path. The coolant plate assembly also includes a first planar section having a first surface facing the energy storage unit and a second surface having a protrusion extending into the coolant channel.

Description

Technical Field

[0001] The present disclosure relates to the field of rechargeable energy storage systems, and more particularly to a rechargeable energy storage system for a vehicle including a battery pack having an integrated cooling system. Background Art

[0002] A rechargeable energy storage system (RESS) typically includes one or more battery packs with rechargeable energy storage cells. The battery packs may be connected to an external charging system that replenishes the electrical energy lost to a load. The charging system may be part of the vehicle, or may be part of an external charging station. When powering the vehicle, the battery packs release the stored electrical energy. Replenishing and releasing the stored electrical energy generates heat that, if not removed, may reduce the efficiency of the battery pack.

[0003] There are a wide range of systems for cooling batteries. For example, many batteries will include a forced air convection system that delivers a stream of air over the battery components. Other systems may employ a heat sink that absorbs heat. The absorbed heat may be given up to the forced air flow. Still other systems may employ a cold plate. The cold plate is typically formed of aluminum and may include internal channels that circulate a fluid. The fluid absorbs heat that may be emitted from the battery pack that is in thermal contact with the cold plate. Summary of the invention

[0004] A battery pack is disclosed herein. The battery pack includes a first header having a first pipe and a second header having a second pipe. The battery pack also includes an energy storage system having an energy storage unit arranged between the first header and the second header. A coolant plate assembly is arranged between the first header and the second header and adjacent to a plurality of energy storage units. The coolant plate assembly includes a coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and an intermediate portion defining a flow path. The coolant plate assembly also includes a first flat section having a first surface facing the energy storage unit and a second surface having a protrusion extending into the coolant channel.

[0005] Another aspect of the present disclosure may be wherein the first plurality of protrusions comprise different heights relative to the second surface of the first planar section.

[0006] Another aspect of the present disclosure may be wherein the first plurality of protrusions are arranged in columns, wherein the first plurality of protrusions in adjacent columns are offset relative to each other in a direction perpendicular to a coolant fluid flow direction through the coolant channel.

[0007] Another aspect of the present disclosure includes another group of energy storage cells arranged between the first header and the second header and spaced apart from the energy storage cells. Another coolant plate assembly is arranged between the first header and the second header and adjacent to each of the other group of energy storage cells. The other coolant plate includes another coolant channel having a first end fluidly connected to the first conduit, a second end fluidly connected to the second conduit, and an intermediate section defining another flow path. The other coolant plate assembly includes a second flat section having a first surface facing the other group of energy storage cells and a second surface having a second protrusion extending into the other coolant channel.

[0008] Another aspect of the present disclosure may be wherein the second plurality of protrusions comprise different heights relative to the second surface.

[0009] Another aspect of the present disclosure may be wherein the second plurality of protrusions are arranged in columns, wherein the second plurality of protrusions in adjacent columns are offset relative to each other in a direction perpendicular to coolant flow through another coolant channel.

[0010] Another aspect of the present disclosure may be wherein a first surface on a first planar section of a coolant plate assembly is coated with a thermal interface material that directly engages a plurality of energy storage cells, and a first surface on a second planar section of another coolant plate is coated with a thermal interface material that directly engages another plurality of energy storage cells.

[0011] Another aspect of the present disclosure may be wherein the coolant plate assembly includes a first curved segment having a first inner surface and a first outer surface facing the coolant channel, and the other coolant plate assembly includes a second curved segment having a second inner surface and a second outer surface facing the other coolant channel.

[0012] Another aspect of the present disclosure may be wherein the first outer surface of the coolant plate assembly abuts the second outer surface of the other coolant plate assembly at a coolant plate interface.

[0013] Another aspect of the present disclosure may include a first air gap disposed at a first side of the coolant plate interface and a second air gap disposed at a second side of the coolant plate interface.

[0014] Another aspect of the disclosure may be wherein the first plurality of protrusions each include a perimeter wall extending from a first surface of the first planar section to a first outwardly facing surface, and the second plurality of protrusions each include a perimeter wall extending from a second surface of the second planar section to the outwardly facing surface.

[0015] Another aspect of the present disclosure may be wherein the first conduit includes a first coolant inlet conduit and a first coolant outlet conduit, and the second conduit includes a second coolant inlet conduit and a second coolant outlet conduit, the first coolant inlet conduit being fluidly connected to the second coolant outlet conduit, and the second coolant inlet conduit being fluidly connected to the first coolant outlet conduit.

[0016] A vehicle is disclosed herein. The vehicle includes a body defining a passenger compartment, an electric motor supported in the body, and a battery pack connected to the electric motor. The battery pack includes a first header having a first pipe and a second header having a second pipe. The battery pack also includes an energy storage system having an energy storage unit arranged between the first header and the second header. A coolant plate assembly is arranged between the first header and the second header and adjacent to a plurality of energy storage units. The coolant plate assembly includes a coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and a middle portion defining a flow path. The coolant plate assembly also includes a first flat section having a first surface facing the energy storage unit and a second surface having a protrusion extending into the coolant channel.

[0017] A coolant system is disclosed herein. The coolant system includes a coolant plate assembly arranged between a first header and a second header. The coolant plate assembly includes a coolant channel having a first end fluidly connected to a first pipe, a second end fluidly connected to a second pipe, and an intermediate portion defining a flow path. The coolant plate assembly also includes a first flat section having a first surface for facing at least one first energy storage unit and a second surface at least partially defining a coolant channel and having a first group of protrusions extending into the coolant channel. The coolant system also includes another coolant plate assembly arranged between the first header and the second header. Another coolant plate assembly includes another coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and an intermediate section defining another flow path. The other coolant plate also includes a second flat section having a first surface for facing at least one second energy storage unit and a second surface having a second group of protrusions extending into the other coolant channel.

[0018] Solution 1. A battery pack comprising:

[0019] a first header including a first conduit;

[0020] a second header including a second conduit;

[0021] an energy storage system comprising a plurality of energy storage cells arranged between a first header and a second header; and

[0022] A coolant plate assembly is arranged between the first header and the second header and adjacent to the plurality of energy storage cells, the coolant plate assembly comprising a coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and a middle portion defining a flow path, wherein the coolant plate assembly comprises a first flat section having a first surface facing the plurality of energy storage cells and a second surface having a first plurality of protrusions extending into the coolant channel.

[0023] Option 2. The battery pack according to Option 1, wherein the first plurality of protrusions include different heights relative to the second surface of the first planar section.

[0024] Option 3. The battery pack according to Option 1, wherein the first plurality of protrusions are arranged in columns, wherein the first plurality of protrusions in adjacent columns are offset relative to each other in a direction perpendicular to a direction of coolant fluid flow through the coolant channel.

[0025] Solution 4. The battery pack according to Solution 1, comprising:

[0026] an additional plurality of energy storage cells disposed between the first header and the second header and spaced apart from the plurality of energy storage cells; and

[0027] another coolant plate assembly disposed between the first header and the second header and adjacent to each of the additional plurality of energy storage cells, the other coolant plate assembly comprising another coolant channel having a first end fluidly connected to the first conduit, a second end fluidly connected to the second conduit, and an intermediate section defining another flow path, wherein the other coolant plate assembly comprises a second flat section having a first surface facing the additional plurality of energy storage cells and a second surface having a second plurality of protrusions extending into the other coolant channel.

[0028] Option 5. The battery pack according to Option 4, wherein the second plurality of protrusions include different heights relative to the second surface.

[0029] Embodiment 6. The battery pack according to embodiment 4, wherein the second plurality of protrusions are arranged in columns, wherein the second plurality of protrusions in adjacent columns are offset relative to each other in a direction perpendicular to the coolant flow through another coolant channel.

[0030] Option 7. A battery pack according to Option 4, wherein the first surface on the first flat section of the coolant plate assembly is coated with a thermal interface material that directly bonds to multiple energy storage cells, and the first surface on the second flat section of another coolant plate is coated with another thermal interface material that directly bonds to another plurality of energy storage cells.

[0031] Option 8. A battery pack according to Option 4, wherein the coolant plate assembly includes a first curved segment having a first inner surface and a first outer surface facing the coolant channel, and the other coolant plate assembly includes a second curved segment having a second inner surface and a second outer surface facing the other coolant channel.

[0032] Embodiment 9. The battery pack of embodiment 8, wherein the first outer surface of the coolant plate assembly abuts the second outer surface of the other coolant plate assembly at a coolant plate interface.

[0033] Embodiment 10. The battery pack of embodiment 9 comprises a first air gap arranged at a first side of the coolant plate interface and a second air gap arranged at a second side of the coolant plate interface.

[0034] Option 11. A battery pack according to Option 4, wherein each of the first plurality of protrusions includes a peripheral wall extending from a first surface of the first planar section to a first outward-facing surface, and each of the second plurality of protrusions includes another peripheral wall extending from a second surface of the second planar section to an outward-facing surface.

[0035] Option 12. A battery pack according to Option 1, wherein the first conduit includes a first coolant inlet conduit and a first coolant outlet conduit, and the second conduit includes a second coolant inlet conduit and a second coolant outlet conduit, the first coolant inlet conduit is fluidly connected to the second coolant outlet conduit, and the second coolant inlet conduit is fluidly connected to the first coolant outlet conduit.

[0036] Solution 13. A vehicle, comprising:

[0037] a body defining a passenger compartment;

[0038] an electric motor supported in the vehicle body; and

[0039] A battery pack operatively connected to the electric motor, the battery pack comprising:

[0040] a first header including a first conduit;

[0041] a second header including a second conduit;

[0042] a plurality of energy storage cells disposed between the first header and the second header; and

[0043] A coolant plate assembly is arranged between a first header and a second header and adjacent to a plurality of energy storage cells, the coolant plate assembly comprising a coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and a middle portion defining a flow path, wherein the coolant plate assembly comprises a first flat section having a first surface facing the plurality of energy storage cells and a second surface having a first plurality of protrusions extending into the coolant channel.

[0044] Solution 14. The vehicle according to Solution 13, further comprising:

[0045] an additional plurality of energy storage cells disposed between the first header and the second header and spaced apart from the plurality of energy storage cells; and

[0046] another coolant plate assembly disposed between the first header and the second header and adjacent to each of the additional plurality of energy storage cells, the other coolant plate assembly comprising another coolant channel having a first end fluidly connected to the first conduit, a second end fluidly connected to the second conduit, and an intermediate section defining another flow path, wherein the other coolant plate assembly comprises a second flat section having a first surface facing the additional plurality of energy storage cells and a second surface having a second plurality of protrusions extending into the other coolant channel.

[0047] Embodiment 15. The vehicle of embodiment 14, wherein the first surface on the coolant plate assembly and the first surface on the other coolant plate assembly are each coated with a thermal interface material.

[0048] Option 16. A vehicle according to Option 15, wherein the coolant plate assembly includes a first curved segment having a first inner surface and a first outer surface facing the coolant channel, and the other coolant plate assembly includes a second curved segment having a second inner surface and a second outer surface facing the other coolant channel.

[0049] Option 17. A vehicle according to Option 16, wherein the first outer surface of the coolant plate assembly is adjacent to the second outer surface of the other coolant plate assembly at a coolant plate interface, the first air gap is arranged at a first side of the coolant plate interface, and the second air gap is arranged at a second side of the coolant plate interface.

[0050] Embodiment 18. The vehicle of embodiment 14, wherein the first plurality of protrusions include different heights relative to the first surface of the first planar section, and the second plurality of protrusions include different heights relative to the first surface of the second planar section.

[0051] Option 19. A vehicle according to Option 14, wherein the first plurality of protrusions are arranged in rows, wherein the protrusions in adjacent rows are offset relative to each other in a direction perpendicular to the coolant flow through the coolant channel, and the second plurality of protrusions are arranged in rows, wherein the protrusions in adjacent rows are offset relative to each other in a direction perpendicular to the coolant flow through another coolant channel.

[0052] Solution 20. A battery pack coolant system, comprising:

[0053] a coolant plate assembly disposed between the first header and the second header, the coolant plate assembly including a coolant channel having a first end fluidly connected to the first conduit, a second end fluidly connected to the second conduit, and a middle portion defining a flow path, wherein the coolant plate assembly includes a first planar section having a first surface for facing the at least one first energy storage cell and a second surface at least partially defining the coolant channel and having a first plurality of protrusions extending into the coolant channel; and

[0054] another coolant plate assembly arranged between the first header and the second header, the another coolant plate assembly comprising another coolant channel, the another coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and an intermediate section defining another flow path, wherein the another coolant plate comprises a second flat section having a first surface for facing at least one second energy storage unit and a second surface having a second plurality of protrusions extending into the another coolant channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0056] Figure 1 is a left side view of a vehicle including a rechargeable energy storage system having a battery pack including an integrated cooling system according to a non-limiting example.

[0057] Figure 2 is a schematic diagram of a portion of a battery pack including a first plurality of cells and a second plurality of cells separated by a first coolant plate and a second coolant plate according to a non-limiting example.

[0058] Figure 3 is an exploded view of a first plurality of cells and a second plurality of cells and first and second coolant plates according to a non-limiting example.

[0059] Figure 4 According to non-limiting examples Figure 3 An end view of one of the first plurality of cells and one of the second plurality of cells and first and second coolant plates including a volume of coolant fluid.

[0060] Figure 5 is a perspective view of an enlarged view of a first coolant plate according to a non-limiting example.

[0061] Figure 6 is a side view of a first planar section having a plurality of aligned protrusions according to a non-limiting example.

[0062] Figure 7 is a side view of a first planar section having a plurality of staggered protrusions according to a non-limiting example.

[0063] Figure 8 is a schematic diagram of an end view of another first coolant plate assembly and a second coolant plate assembly having protrusions of the same height according to a non-limiting example.

[0064] Fig. 9 is a schematic diagram of an end view of yet another first coolant plate assembly and a second coolant plate assembly having protrusions of different heights according to a non-limiting example.

[0065] Fig.10 is a schematic diagram of a first planar section forming a first or second coolant plate assembly according to a non-limiting example.

[0066] Fig.11 According to a non-limiting example, Fig.10 Schematic diagram of attaching the first flat section formed in FIG. 1 to an energy storage unit. DETAILED DESCRIPTION

[0067] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses.It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0068] According to a non-limiting example, the vehicle Figure 1 1. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. One or more of the plurality of wheels 16 are steerable. The body 12 partially defines a passenger compartment 20 having seats 23 located behind an instrument panel 26. A steering controller 30 is disposed between the seats 23 and the instrument panel 26. The steering controller 30 is operated to control the orientation of the steerable wheels.

[0069] The vehicle 10 includes an electric motor 34 connected to a transmission 36 that provides power to one or more of the plurality of wheels 16. A rechargeable energy storage system (RESS) 38 is disposed in the vehicle body 12 and provides power to the electric motor 34. In this regard, it should be understood that the locations of the electric motor 34, the transmission 36, and the RESS 38 in the vehicle body 12 may vary. Figure 2 and Figure 3 , the RESS 38 includes a battery pack 40 that includes an energy storage system generally indicated at 42 .

[0070] The energy storage system 42 is arranged between a first header 44 and a second header 46. The first header 44 includes a first interior 48 and the second header 46 includes a second interior 50. In the non-limiting example shown, the energy storage system 42 includes a first row of energy storage cells 51 and a second row of energy storage cells 52 arranged side by side and parallel to the first row of energy storage cells 51. Although two rows of energy storage cells 51, 52 are discussed, it should be understood that the number and arrangement of the rows of energy storage cells arranged between the first header 44 and the second header 46 may be different.

[0071] The first energy storage cell row 51 includes a first plurality of energy storage cells 54, and the second energy storage cell row 52 includes a second plurality of energy storage cells 55. The first plurality of energy storage cells 54 includes a first energy storage cell 56, a second energy storage cell 57, a third energy storage cell 58, and a fourth energy storage cell 59. The second plurality of energy storage cells 55 includes a fifth energy storage cell 62, a sixth energy storage cell 63, a seventh energy storage cell 64, and an eighth energy storage cell 65. The number of cells in each energy storage cell row may be different.

[0072] Now refer to Figure 3 and Figure 4 And continue to refer to Figure 2 1 and 2 are used to describe the first energy storage cell 56 and the fifth energy storage cell 62, it is understood that the remaining energy storage cells 57-59 and 63-65 include similar structures. In a non-limiting example, the first energy storage cell 56 includes a first surface 67, a second surface 69 generally parallel to the first surface 67, a third surface 71 extending between the first surface 67 and the second surface 69, and a fourth surface 73 generally parallel to the third surface 71. The first energy storage cell 56 includes additional surfaces (not separately labeled). Electrical connection elements shown in the form of an anode 75 and a cathode 77 are arranged on the third surface 71.

[0073] The fifth energy storage cell 62 includes a first surface portion 80, a second surface portion 82 generally parallel to the first surface portion 80, a third surface portion 84 extending between the first surface portion 80 and the second surface portion 82, and a fourth surface portion 86 generally parallel to the third surface portion 84. The fifth energy storage cell 62 includes additional surfaces (not separately labeled). Electrical connection elements shown in the form of an anode member 88 and a cathode member 90 are arranged on the third surface portion 84.

[0074] In a non-limiting example, the battery pack 40 includes a first coolant plate assembly 93 disposed on the second surface 69 of each of the first plurality of energy storage cells 54 and a second coolant plate assembly 95 disposed on the first surface portion 80 of each of the second plurality of energy storage cells 55. In a non-limiting example, the first coolant plate assembly 93 and the second coolant plate assembly 95 are adjacent to each other and disposed between adjacent rows of energy storage cells, such as Figure 2 as shown in .

[0075] exist Figure 3-5 In the non-limiting example shown in FIG, the first coolant plate assembly 93 includes a first flat section 99 and a first curvilinear section 102, the first flat section 99 and the first curvilinear section 102 together at least partially defining a first coolant channel 104. The first flat section 99 includes a first surface 99A and a second surface 99B opposite the first surface 99A, the first surface 99A facing each of the first plurality of energy storage units 54 and fixed relative thereto, and the second surface 99B at least partially defining the first coolant channel 104. The first surface 99A can be formed by a first adhesive member 103 ( Figure 4 ) is directly attached to the first plurality of energy storage cells 54. The first curvilinear segment 102 includes an inner surface 102A facing the first coolant passage 104 and an outer surface 102B facing away from the first coolant passage 104. The first coolant passage 104 extends between a first end 106 disposed at the first header 44 and a second end 108 disposed at the second header 46.

[0076] In a non-limiting example, the second coolant plate assembly 95 includes a second flat section 112 and a second curvilinear section 114, which together at least partially define a second coolant channel 116. The second flat section 112 includes a first surface 112A and a second surface 112B opposite the first surface 112A, the first surface 112A facing each of the second plurality of energy storage cells 55 and fixed relative thereto, and the second surface 112B at least partially defines the second coolant channel 116. The first surface 112A can be directly attached to the second plurality of energy storage cells 55 by a second adhesive member 115. The second curvilinear section 114 includes an inner surface 114A facing the second coolant channel 116 and an outer surface 114B facing away from the second coolant channel 116. The outer surface 114B on the second coolant plate assembly 95 abuts the outer surface 102B on the first coolant plate assembly 93 at an interface. The second coolant passage 116 extends between a first end section 118 arranged at the first header 44 and a second end section 120 arranged at the second header 46 .

[0077] exist Figure 2 In the non-limiting example shown in FIG. 1 , a first coolant inlet conduit 122 extends through the first header 44 and is fluidly connected to the first coolant passage 104 at the first end 106. A first coolant outlet conduit 123 extends through the first header 44 and is fluidly connected to the second coolant passage 116 at the first end section 118. In this regard, it should be understood that the first coolant inlet conduit 122 and the first coolant outlet conduit 123 are fluidly connected to coolant passages (not separately labeled) that pass through the remaining coolant plates of the first and second coolant plates.

[0078] like Figure 2 As further shown in FIG. 1 , a second coolant inlet conduit 124 extends through the second header 46 and is fluidly connected to the second coolant passage 116 at the second end section 120. A second coolant outlet conduit 125 extends through the second header 46 and is fluidly connected to the second end 108 of the first coolant passage 104. The particular arrangement of the coolant inlet conduits 122 and 124 and the coolant outlet conduits 123 and 125 creates a lateral flow between adjacent energy storage cell rows 51 and 52. The lateral flow enhances the heat exchange efficiency between the coolant flowing through the first coolant passage 104 and the second coolant passage 116 and the first and second pluralities of energy storage cells 54 and 55.

[0079] In this regard, it should be understood that the coolant fluid flowing through the first coolant plate assembly 93 and the second coolant plate assembly 95 can be driven by a pump (not shown) and sent through a heat exchanger (also not shown). The first and second coolant inlet pipes 122 and 124 are fluidly connected by a cooling supply line 126, which in turn is fluidly connected to the pump (not shown), and the first coolant outlet pipe 123 and the second coolant outlet pipe 125 can direct the fluid carrying heat through the coolant outlet line 127 and continue into the heat exchanger (also not shown).

[0080] refer to Figure 4 , the first coolant fluid 128 flows through the first coolant channel 104 and the second coolant fluid 129 flows through the second coolant channel 116. The specific type of coolant fluid can vary and can include liquid coolants (e.g., aqueous solutions, ethylene glycol solutions, etc.) as well as gaseous coolants. In addition to the coolant fluid, air can also pass through the gap 130 formed when the outer surfaces 102B, 114B on the first and second coolant plate assemblies 93, 95 are respectively. The air can be a forced convection air flow directed over the battery pack 40.

[0081] Additionally, the gap 130 between the first coolant plate assembly 93 and the second coolant plate assembly 95 can accommodate a certain amount of compression generated by operating the battery pack 40 by allowing, for example, a certain amount of deformation of the first curve segment 102 and / or the second curve segment 114. The amount of deformation of the first curve segment 102 and / or the second curve segment 114 can be between about 0.1 mm and about 2 mm.

[0082] like Figure 4-7 As shown in FIG. 1 , the first coolant plate assembly 93 includes a first plurality of protrusions 117 extending in a direction away from the first energy storage unit 54 and into the first coolant channel 104. Similarly, the second coolant plate assembly 95 includes a second plurality of protrusions 117 and a second plurality of protrusions 119 extending in a direction away from the second plurality of energy storage units 55 and into the second coolant channel 116. In the example shown, the first and second pluralities of protrusions 117, 119 are arranged in rows that extend perpendicular to the direction of coolant fluid flow through the first and second coolant channels 104, 116, respectively.

[0083] like Figure 6 and Figure 7 As shown in FIG. 1 , the protrusions 117 on the first flat section 99 may have different arrangements, depending on the level of local turbulence that is desired to be generated in the coolant fluid flow. Figure 6 and Figure 7The first flat section 99 is shown, and the arrangement of the protrusions 117 shown will also apply to the protrusions 119 on the second flat section 112 of the second coolant plate assembly 95. In one example, the protrusions 117 include a vertical distance D1 between two adjacent protrusions 117, and the vertical distance D1 is less than five times the equivalent diameter D0 of the protrusion 117. In this example, vertical is in a direction perpendicular to the coolant fluid flow F through the first channel 104. In addition, the horizontal distance D2 between adjacent protrusions 117 should be less than ten times the equivalent diameter D0 of the protrusion 117 to increase local turbulence in the coolant fluid flow F, thereby improving heat transfer. In addition, the protrusions 117 can be arranged in a grid of aligned rows and columns, such as Figure 7 As shown in , the first plurality of protrusions 117 may alternatively be arranged in rows, wherein adjacent rows are offset relative to each other in a direction perpendicular to the coolant fluid flow F through the first coolant channel 104 .

[0084] Figure 8 First and second cooling plate assemblies 93, 95 are shown having another example set of first and second pluralities of protrusions 117-1, 119-1, respectively. The first and second pluralities of protrusions 117-1, 119-1 are similar to the first and second pluralities of protrusions 117 and 119 disclosed above, except as shown in the figures described below. In the example shown, the first and second pluralities of protrusions 117-1, 119-1 include different spacings between adjacent protrusions 117-1, 119-1 in a direction perpendicular to the flow direction of coolant flow through the first and second coolant channels 104, 116 in the first and second cooling plate assemblies 93, 95, respectively. In particular, the spacing between the first and second pluralities of protrusions 117-1, 119-1 in the middle region of the columns of the first and second coolant channels 104, 116 is less than the spacing between adjacent first and second protrusions 117-1, 119-1 along the edges of the first and second coolant channels 104, 116, respectively. One feature of the variable spacing is to increase heat transfer by changing the turbulence induced in the coolant fluid flow in the first and second coolant channels 104 , 116 .

[0085] Fig. 9First and second cooling plate assemblies 93, 95 are shown, respectively having yet another example set of first and second pluralities of protrusions 117S-2, 117T-2, 119S-2, 119T-2. Except as shown in the figures described below, the first and second pluralities of protrusions 117S-2, 117T-2, 119S-2, 119T-2 are similar to the first and second pluralities of protrusions 117 and 119 disclosed above. In the example shown, the first and second pluralities of protrusions 117S-2, 117T-2, 119S-2, 119T-2 include different spacings between adjacent protrusions 117S-2, 117T-2, 119S-2, 119T-2 in a direction perpendicular to the direction of coolant fluid flow through the first and second coolant channels 104, 116 in the first and second cooling plate assemblies 93, 95, respectively. In addition, the first and second plurality of protrusions 117S-2, 117T-2, 119S-2, 119T-2 protrude from the second surface 99B and 112B by different distances, respectively, so that the heights of the first and second plurality of protrusions 117S-2, 117T-2, 119S-2, 119T-2 are different. In particular, the heights of the first and second plurality of protrusions 117-2, 119-2 in the middle region of the first and second coolant channels 104, 116 are greater than the heights of the first and second protrusions 117S-2, 117T-2, 119S-2, 119T-2 along the edges of the first and second coolant channels 104, 116, respectively.

[0086] The protrusions 117-1, 117S-2, 117T-2, 119-1, 119S-2, 119T-2 may provide a mechanical stop to limit compression of the first and second curvilinear segments 102, 114 to ensure space for maintaining a desired coolant fluid flow rate. The arrangement of the protrusions 117, 119 may be configured to accommodate uneven compression of the interlayer. For example, compared to the top and bottom edges along the second surface 99B, 112B, Fig. 9 The protrusions 117T-2, 119T-2 shown in the central region may extend a greater distance from the second surface 99B, 112B. Fig. 9 This configuration of the first and second pluralities of protrusions 117S- 2 , 117T- 2 , 119S- 2 , 119T- 2 in the coolant plate assembly allows for less deflection of the first and second curvilinear segments 102 , 114 prior to engaging the protrusions on the adjacent coolant plate assemblies 93 , 95 .

[0087] like Fig.10As shown in , the first flat section 99 of the first coolant plate assembly 93 can be formed by using a convex roller 150 configured to roll in a direction R1 and a corresponding concave roller 152 configured to roll in a direction R2 to form the protrusion 117. However, the rollers 150, 152 can be used to form the first flat section 112 for the second coolant plate assembly 95 in the same manner as described for the first coolant plate assembly 93. In particular, the material is fed into the rollers 150, 152 in the direction P so that the convex portion 156 of the roller 150 can squeeze the material into the corresponding concave portion 158 on the roller 152 to form the protrusion 117.

[0088] like Fig.11 As shown in , the first planar section 99 may include a thermal interface material 160, such as [Inventor: Please provide example material], placed on the first surface 99A. The thermal interface material increases the heat transfer between the first coolant plate assembly 93 and the first plurality of energy storage cells 54 by filling the voids in the first surface 99A, thereby improving the heat transfer. The first planar surface 99A of the second coolant plate assembly 95 can be attached to the second plurality of energy storage cells 55 in a similar manner. Moreover, the thermal interface material can replace the adhesive 103, 105 ( Figure 4 ) or used in addition to the adhesives 103, 105, for attaching the first and second coolant plate assemblies 93, 95 to the first and second pluralities of energy storage cells 54, 55, respectively.

[0089] The terms "one" and "an" do not indicate a quantitative limitation, but rather indicate the presence of at least one of the referenced items. The term "or" means "and / or" unless the context clearly indicates otherwise. References to "an aspect" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0090] Although various embodiments have been described, the description is intended to be exemplary rather than restrictive. It will be apparent to those of ordinary skill in the art that, within the scope of the embodiments, many more embodiments and implementations are possible. Any feature of any embodiment may be used in combination with any other feature or element in any other embodiment or replace any other feature or element in any other embodiment, unless explicitly limited. Therefore, the embodiments are not limited except according to the attached claims and their equivalents. In addition, various modifications and changes may be made within the scope of the attached claims.

Claims

1. A battery pack comprising: a first header including a first conduit; a second header including a second conduit; an energy storage system comprising a plurality of energy storage cells disposed between a first header and a second header; as well as A coolant plate assembly is arranged between the first header and the second header and adjacent to the plurality of energy storage cells, the coolant plate assembly comprising a coolant channel having a first end fluidly connected to the first pipe, a second end fluidly connected to the second pipe, and a middle portion defining a flow path, wherein the coolant plate assembly comprises a first flat section having a first surface facing the plurality of energy storage cells and a second surface having a first plurality of protrusions extending into the coolant channel.

2. The battery pack according to claim 1, wherein: The first plurality of protrusions include different heights relative to the second surface of the first planar section.

3. The battery pack according to claim 1, wherein: The first plurality of protrusions are arranged in columns, wherein the first plurality of protrusions in adjacent columns are offset relative to each other in a direction perpendicular to a coolant fluid flow direction through the coolant channel.

4. The battery pack according to claim 1, comprising: an additional plurality of energy storage cells disposed between the first header and the second header and spaced apart from the plurality of energy storage cells; as well as another coolant plate assembly disposed between the first header and the second header and adjacent to each of the additional plurality of energy storage cells, the other coolant plate assembly comprising another coolant channel having a first end fluidly connected to the first conduit, a second end fluidly connected to the second conduit, and an intermediate section defining another flow path, wherein the other coolant plate assembly comprises a second flat section having a first surface facing the additional plurality of energy storage cells and a second surface having a second plurality of protrusions extending into the other coolant channel.

5. The battery pack according to claim 4, wherein: The second plurality of protrusions include different heights relative to the second surface.

6. The battery pack according to claim 4, wherein: The second plurality of protrusions are arranged in columns, wherein the second plurality of protrusions in adjacent columns are offset relative to each other in a direction perpendicular to coolant flow through another coolant channel.

7. The battery pack according to claim 4, wherein: A first surface on a first planar section of the coolant plate assembly is coated with a thermal interface material that directly engages a plurality of energy storage cells, and a first surface on a second planar section of another coolant plate is coated with another thermal interface material that directly engages another plurality of energy storage cells.

8. The battery pack according to claim 4, wherein: The coolant plate assembly includes a first curvilinear segment having a first inner surface and a first outer surface facing the coolant channel, and the other coolant plate assembly includes a second curvilinear segment having a second inner surface and a second outer surface facing the other coolant channel.

9. The battery pack according to claim 8, wherein: The first outer surface of the coolant plate assembly abuts the second outer surface of the other coolant plate assembly at a coolant plate interface. 10 . The battery pack of claim 9 , comprising a first air gap disposed at a first side of the coolant plate interface and a second air gap disposed at a second side of the coolant plate interface.

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