Three-layer bubble sheet cooling plate

Abstract

A method of manufacturing a cold plate includes stacking three aluminum sheets on top of each other while each of the three aluminum sheets is substantially flat. And the edges of the three aluminum sheets are fixed together. A top aluminum sheet of the aluminum sheets is welded to an intermediate aluminum sheet of the aluminum sheets at a plurality of first locations, and a bottom aluminum sheet of the aluminum sheets is welded to the intermediate aluminum sheet of the aluminum sheets at a plurality of second locations different from the plurality of first locations. A pressurized medium is supplied between a top aluminum sheet of the aluminum sheet and a bottom aluminum sheet of the aluminum sheet to separate the top aluminum sheet of the aluminum sheet from the bottom aluminum sheet of the aluminum sheet and deform a middle aluminum sheet of the aluminum sheet.

Description

Technical Field

[0001] The present disclosure relates to a three-layer bubble sheet cooling plate and a method for making the same. Background Art

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. To the extent described in this section, the work of the presently named inventors and aspects of the description that may not otherwise be prior art at the time of filing are neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0003] Cold plates are mainly made using two manufacturing techniques including extrusion and brazing. Cold plates made by extrusion have thick walls, typically greater than 0.4-0.5mm thick. In addition, the extrusion process is limited to the shape and size of the panel. Brazing is a slow and expensive process that requires many fixtures and special fabrication.

[0004] It would therefore be desirable to provide an alternative method of manufacturing cooling plates having reduced cost and time requirements. Summary of the invention

[0005] According to one aspect of the present disclosure, a method for manufacturing a cold plate includes: stacking three metal sheets on top of each other, while each of the three metal sheets is substantially flat. The metal sheets may include aluminum, copper, steel, steel alloys or other conductive metals and combinations thereof. The edges of the three metal sheets are welded or otherwise fixed together. The top metal sheet of the metal sheets is bonded to the middle metal sheet of the metal sheets at a plurality of first positions, and the bottom metal sheet of the metal sheets is bonded to the middle metal sheet of the metal sheets at a plurality of second positions different from the plurality of first positions. A pressurized medium is supplied between the top metal sheet of the metal sheets and the bottom metal sheet of the metal sheets to separate the top metal sheet of the metal sheets from the bottom metal sheet of the metal sheets and to deform the middle metal sheet of the metal sheets.

[0006] According to another aspect, a middle one of the aluminum sheets may be thinner than both a top one of the aluminum sheets and a bottom one of the aluminum sheets.

[0007] According to another aspect, the pressurized medium is pressurized air.

[0008] According to another aspect, one of the top aluminum sheet and the bottom aluminum sheet includes a coolant inlet port, and one of the top aluminum sheet and the bottom aluminum sheet includes a coolant outlet port.

[0009] According to another aspect, bonding the top aluminum sheet of the aluminum sheets to the middle aluminum sheet of the aluminum sheets and bonding the bottom aluminum sheet of the aluminum sheets to the middle sheet of the sheets includes one of laser welding, friction welding, resistance welding, and roll bonding.

[0010] According to another aspect, bonding the edges of the three sheets together includes one of laser welding, friction welding, resistance welding, and roll bonding.

[0011] According to another aspect, bonding a top one of the aluminum sheets to a middle one of the aluminum sheets at a plurality of first locations and bonding a bottom one of the aluminum sheets to a middle one of the aluminum sheets at a plurality of second locations each include a plurality of line welds.

[0012] According to another aspect, joining a top one of the aluminum sheets to a middle one of the aluminum sheets at a plurality of first locations and joining a bottom one of the aluminum sheets to a middle one of the aluminum sheets at a plurality of second locations each include a plurality of tack welds.

[0013] Solution 1. A method for manufacturing a cold plate, comprising:

[0014] stacking three metal sheets on top of each other while each of the three metal sheets is substantially flat;

[0015] fastening the edges of the three metal sheets together;

[0016] bonding a top metal sheet of the metal sheets to a middle metal sheet of the metal sheets at a plurality of first locations;

[0017] joining a bottom metal sheet of the metal sheets to a middle metal sheet of the metal sheets at a plurality of second locations different from the plurality of first locations;

[0018] A pressurized medium is supplied between a top metal sheet among the metal sheets and a bottom metal sheet among the metal sheets to separate the top metal sheet among the metal sheets from the bottom metal sheet among the metal sheets and to deform a middle metal sheet among the metal sheets.

[0019] Option 2. The method according to Option 1, wherein a middle metal sheet among the metal sheets is thinner than both a top metal sheet among the metal sheets and a bottom metal sheet among the metal sheets.

[0020] Option 3. The method according to Option 1, wherein the pressurized medium is pressurized air.

[0021] Option 4. The method according to Option 1, wherein one of the top metal sheet and the bottom metal sheet includes a coolant inlet port, and one of the top metal sheet and the bottom metal sheet includes a coolant outlet port.

[0022] Option 5. A method according to Option 1, wherein bonding the top metal sheet in the metal sheet to the middle metal sheet in the metal sheet and bonding the bottom metal sheet in the metal sheet to the middle sheet in the sheet includes one of laser welding, friction welding, resistance welding and roll bonding.

[0023] Option 6. A method according to Option 1, wherein fixing the edges of the three metal sheets together includes one of laser welding, friction welding, resistance welding and roll bonding.

[0024] Option 7. A method according to Option 1, wherein the top metal sheet in the metal sheet is joined to the middle metal sheet in the metal sheet at multiple first positions and the bottom metal sheet in the metal sheet is joined to the middle metal sheet in the metal sheet at multiple second positions each includes multiple wire welds.

[0025] Option 8. A method according to Option 1, wherein the top metal sheet in the metal sheet is joined to the middle metal sheet in the metal sheet at multiple first positions and the bottom metal sheet in the metal sheet is joined to the middle metal sheet in the metal sheet at multiple second positions each includes multiple positioning welds.

[0026] Solution 9. A method for manufacturing a cold plate, comprising:

[0027] stacking three aluminum sheets on top of each other while each of the three aluminum sheets is substantially flat, wherein a middle aluminum sheet of the aluminum sheets is thinner than both a top aluminum sheet of the aluminum sheets and a bottom aluminum sheet of the aluminum sheets;

[0028] Bonding the edges of the three aluminum sheets together;

[0029] bonding a top aluminum sheet of the aluminum sheets to a middle aluminum sheet of the aluminum sheets at a plurality of first locations;

[0030] bonding a bottom aluminum sheet of the aluminum sheets to a middle aluminum sheet of the aluminum sheets at a plurality of second locations different from the plurality of first locations;

[0031] A pressurized medium is supplied between a top aluminum sheet among the aluminum sheets and a bottom aluminum sheet among the aluminum sheets to separate the top aluminum sheet among the aluminum sheets from the bottom aluminum sheet among the aluminum sheets and to deform a middle aluminum sheet among the aluminum sheets.

[0032] Option 10. The method according to Option 9, wherein the pressurized medium is pressurized air.

[0033] Option 11. The method according to Option 9, wherein the pressurized medium is a liquid.

[0034] Option 12. A method according to Option 9, wherein bonding the top aluminum sheet in the aluminum sheet to the middle aluminum sheet in the aluminum sheet and bonding the bottom aluminum sheet in the aluminum sheet to the middle sheet in the sheet includes one of laser welding, friction welding, resistance welding and roll bonding.

[0035] Option 13. A method according to Option 9, wherein bonding the edges of the three sheets together comprises one of laser welding, friction welding, resistance welding and roll bonding.

[0036] Option 14. A method according to Option 9, wherein the top aluminum sheet in the aluminum sheets is joined to the middle aluminum sheet in the aluminum sheets at multiple first positions and the bottom aluminum sheet in the aluminum sheets is welded to the middle aluminum sheet in the aluminum sheets at multiple second positions, each comprising multiple line welding portions.

[0037] Option 15. A method according to Option 9, wherein the top aluminum sheet in the aluminum sheet is joined to the middle aluminum sheet in the aluminum sheet at multiple first positions and the bottom aluminum sheet in the aluminum sheet is joined to the middle aluminum sheet in the aluminum sheet at multiple second positions each includes multiple positioning welds.

[0038] Embodiment 16. The method according to Embodiment 9, wherein one of the top aluminum sheet and the bottom aluminum sheet includes a coolant inlet port, and one of the top aluminum sheet and the bottom aluminum sheet includes a coolant outlet port.

[0039] Solution 17. A battery module cooling plate, comprising:

[0040] Bottom metal sheet;

[0041] A middle metal sheet is bonded to the bottom metal sheet at a plurality of first intermediate positions along the edges of the middle metal sheet and the bottom metal sheet, and the middle metal sheet is also bonded to the top metal sheet at a plurality of second intermediate positions different from the first intermediate positions along the edges of the middle metal sheet and the top metal sheet, wherein the top metal sheet and the bottom metal sheet are spaced apart from each other and the middle metal sheet is corrugated between the top metal sheet and the bottom metal sheet.

[0042] Embodiment 18. The battery module cooling plate according to Embodiment 17, wherein the middle metal sheet is bonded to the top metal sheet by a plurality of first welding portions, and the middle metal sheet is bonded to the bottom metal sheet by a plurality of second welding portions.

[0043] Option 19. A battery module cooling plate according to Option 17, wherein the middle metal sheet is bonded to the top metal sheet, and the middle metal sheet is bonded to the bottom metal sheet by one of laser welding, friction welding, resistance welding and roll bonding.

[0044] Aspect 20. The battery module cooling plate according to Aspect 17, wherein the middle metal sheet is thinner than both the top metal sheet and the bottom metal sheet.

[0045] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the accompanying drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The present disclosure will be more fully understood from the detailed description and accompanying drawings, wherein:

[0047] Figure 1 is a cross-sectional view of a cold plate according to the principles of the present disclosure.

[0048] FIG2a is a schematic cross-sectional view of a stack of aluminum sheets according to the principles of the present disclosure;

[0049] FIG2 b is a schematic cross-sectional view of multiple welding locations between a stack of aluminum sheets according to the principles of the present disclosure;

[0050] Figure 3 is a schematic plan view of a stack of aluminum sheets according to the principles of the present disclosure, showing exemplary weld lines between a top aluminum sheet and a middle aluminum sheet in the aluminum sheets and between a bottom aluminum sheet and a middle aluminum sheet in the aluminum sheets;

[0051] Figure 4 is a schematic plan view of a stack of aluminum sheets according to the principles of the present disclosure, showing exemplary circular tack welds between a top one of the aluminum sheets and a middle one of the aluminum sheets and between a bottom one of the aluminum sheets and a middle one of the aluminum sheets; and

[0052] Figures 5a-5c illustrate the expansion of the cold plates from their original stacked and welded state to intermediate and final expanded positions.

[0053] Among the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0054] refer to Figure 1 , a three-layer bubble sheet cooling plate 10 according to the principles of the present disclosure is shown. The cooling plate 10 includes a bottom aluminum sheet 12, a middle aluminum sheet 14, and a top aluminum sheet 16. The bottom aluminum sheet 12 is connected to the middle aluminum sheet 14 by a first plurality of welds 18, and the top aluminum sheet 16 is connected to the middle aluminum sheet 14 by a second plurality of welds 20 offset from the first plurality of welds 18.

[0055] Referring to Figures 2a and 2b, a method of manufacturing a three-layer bubble sheet cooling plate 10 according to the principles of the present disclosure will now be described. In Figure 2a, the bottom aluminum sheet 12, the middle aluminum sheet 14, and the top aluminum sheet 16 are stacked on each other, and they are all generally flat sheets. The middle aluminum sheet 14 can be thinner and more flexible than the top aluminum sheet 16 and the bottom aluminum sheet 12. For example, the top and bottom aluminum sheets 12, 16 can be 2 to 4 times thicker than the middle aluminum sheet 14. Then, as shown in Figure 2b, an edge weld 17 or other fixing method is set around the periphery of the stacked aluminum sheet to connect the aluminum sheets 12, 14 and 16 together. Then, the bottom aluminum sheet 12 is connected to the middle aluminum sheet 14 by a plurality of welds 18, and the top aluminum sheet 16 is connected to the middle aluminum sheet 14 by a plurality of welds 20.

[0056] refer to Figure 3 , shows a plan view of a stack of aluminum sheets 12, 14, 16, wherein solid lines 18 show a plurality of elongated welds 18 between the bottom aluminum sheet 12 and the middle aluminum sheet 14. In addition, dashed lines 20 show a plurality of elongated welds 20 between the top aluminum sheet 16 and the middle aluminum sheet 14. The elongated welds 18 and 20 may be straight or curved. The elongated welds 18 and 20 are offset from each other so as to define channels 22, 24 of the bottom aluminum sheet 12 and the middle aluminum sheet 14 and the top aluminum sheet 16 and the middle aluminum sheet 14, respectively. Figure 3 One or both of the bottom aluminum sheet 12 and the top aluminum sheet 16 may be provided with a coolant inlet port 26 and a coolant outlet port 28 .

[0057] With reference to Figures 5a-5c, the expansion process for expanding the aluminum sheets 12,14,16 welded together will now be described.With reference to Figure 5a, the welded stack of aluminum sheets 12,14,16 can be placed in expandable or fixed dye.A pressurized medium source 30 such as pressurized air or liquid can be attached to a coolant inlet port and / or an outlet port for conveying pressurized medium to the passage 22,24 between the stacked aluminum sheets. For thinner aluminum sheets, air can be used, and for thicker aluminum sheets, water or other liquids can be used.With reference to Figure 5b, the structure of the stacked aluminum sheets is partially stretched and the dye upper member is moved to the middle position, and in Figure 5c, the passage 22,24 between the stacked aluminum sheets is fully formed, and the top and bottom sheets arrive at the desired expanded position.Leakage inspection can be carried out during the inflation process.

[0058] Alternatively, if Figure 4, a plan view of a stack of aluminum sheets 12, 14, 16 is shown, wherein the solid circular line 18' shows a plurality of spot welds 18' between the bottom aluminum sheet 12 and the middle aluminum sheet 14. In addition, the dashed circular line 20' shows a plurality of spot welds 20' between the top aluminum sheet 16 and the middle aluminum sheet 14. The spot welds 18' and 20' are offset from each other so as to define channels of the bottom aluminum sheet 12 and the middle aluminum sheet 14 and the top aluminum sheet 16 and the middle aluminum sheet 14, respectively. Figure 4 One or both of the bottom aluminum sheet 12 and the top aluminum sheet 16 may be provided with a coolant inlet port 26 and a coolant outlet port 28 .

[0059] The stack of aluminum sheets 12, 14 and 16 welded together by spot welds 18', 20' can then be expanded by introducing a pressurized medium as described above with reference to Figures 5a-5c. It should be noted that a combination of spot welds and line welds may also be used to form a three-layer bubble sheet cooling plate 10.

[0060] The present disclosure provides a method for manufacturing a predominantly flat double-sided cold plate 10 using welding and inflation techniques. Three flat aluminum sheets are placed on top of each other. Two of the three sheets are joined at a time using controlled partial penetration laser welding or friction welding. Air is passed through the weld stack at a predetermined pressure based on the sheet thickness and the desired channel height to expand the sheets to form a channel structure. The middle sheet is deformed, leaving the two outer sheets flat or substantially flat to interface with the battery wall. Compared to previous cold plate designs, the cold plate requires low-cost, simple tooling. The process avoids the stamping operations and tooling typically required for brazing. A variety of bonding methods are available, including laser welding, friction welding, or roll bonding processes, which can be used with appropriate mask sheets to prevent bonding in masked areas. The mixed area of ​​the coolant channel welded via partial channel can reduce the risk of coolant evaporation during a unit thermal event. A simple process of forming using 3 flat aluminum sheets, without trimming or preforming, provides a reduction in prototype and production costs and time.

[0061] The foregoing description is essentially only illustrative, and is by no means intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because after studying the drawings, the specification and the appended claims, other modifications will become apparent. It should be understood that, without changing the principles of the present disclosure, one or more steps in the method can be performed in different orders (or simultaneously). In addition, although each of the embodiments is described above as having certain features, any one or more of those features described with reference to any embodiment of the present disclosure can be implemented in the features of any one of the other embodiments and / or combined with the features of any one of the other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the replacement of one or more embodiments with each other is still within the scope of the present disclosure.

[0062] Various terms are used to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "above," "below," and "disposed." Unless explicitly described as "direct," when describing the relationship between a first and a second element in the above disclosure, the relationship can be a direct relationship in which there are no other intermediate elements between the first and second elements, but can also be an indirect relationship in which there are one or more intermediate elements (spatially or functionally) between the first and second elements. As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean a logical (A or B or C) using a non-exclusive logical "or," and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

Claims

1. A method for manufacturing a cold plate, comprising: stacking three metal sheets on top of each other while each of the three metal sheets is substantially flat; fastening the edges of the three metal sheets together; bonding a top metal sheet of the metal sheets to a middle metal sheet of the metal sheets at a plurality of first locations; joining a bottom metal sheet of the metal sheets to a middle metal sheet of the metal sheets at a plurality of second locations different from the plurality of first locations; A pressurized medium is supplied between a top metal sheet among the metal sheets and a bottom metal sheet among the metal sheets to separate the top metal sheet among the metal sheets from the bottom metal sheet among the metal sheets and to deform a middle metal sheet among the metal sheets.

2. The method according to claim 1, wherein: A middle metal sheet among the metal sheets is thinner than both a top metal sheet among the metal sheets and a bottom metal sheet among the metal sheets.

3. The method according to claim 1, wherein: The pressurized medium is pressurized air.

4. The method according to claim 1, wherein: One of the top metal sheet and the bottom metal sheet includes a coolant inlet port, and one of the top metal sheet and the bottom metal sheet includes a coolant outlet port.

5. The method according to claim 1, wherein: Bonding the top metal sheet of the metal sheets to the middle metal sheet of the metal sheets and bonding the bottom metal sheet of the metal sheets to the middle sheet of the sheet includes one of laser welding, friction welding, resistance welding and roll bonding.

6. The method according to claim 1, wherein: Fixing the edges of the three metal sheets together includes one of laser welding, friction welding, resistance welding and roll bonding.

7. The method according to claim 1, wherein: Joining a top metal sheet of the metal sheets to a middle metal sheet of the metal sheets at a plurality of first locations and joining a bottom metal sheet of the metal sheets to a middle metal sheet of the metal sheets at a plurality of second locations each include a plurality of line welds.

8. The method according to claim 1, wherein: Joining a top one of the metal sheets to a middle one of the metal sheets at a plurality of first locations and joining a bottom one of the metal sheets to a middle one of the metal sheets at a plurality of second locations each include a plurality of tack welds.

9. A method of manufacturing a cold plate, comprising: stacking three aluminum sheets on top of each other while each of the three aluminum sheets is substantially flat, wherein a middle aluminum sheet of the aluminum sheets is thinner than both a top aluminum sheet of the aluminum sheets and a bottom aluminum sheet of the aluminum sheets; Bonding the edges of the three aluminum sheets together; bonding a top aluminum sheet of the aluminum sheets to a middle aluminum sheet of the aluminum sheets at a plurality of first locations; bonding a bottom aluminum sheet of the aluminum sheets to a middle aluminum sheet of the aluminum sheets at a plurality of second locations different from the plurality of first locations; A pressurized medium is supplied between a top aluminum sheet among the aluminum sheets and a bottom aluminum sheet among the aluminum sheets to separate the top aluminum sheet among the aluminum sheets from the bottom aluminum sheet among the aluminum sheets and to deform a middle aluminum sheet among the aluminum sheets.

10. The method according to claim 9, wherein: The pressurized medium is pressurized air.

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