Multifunctional integrated structure hot plate

Abstract

A multi-functional unitary thermal plate and system for supporting a plurality of battery cells included as part of a high voltage battery pack. The plate may include a bottom plate configured to support the battery cells and a plurality of cross beams, wherein the bottom plate and the cross beams together form a unitary, one-piece structure.

Description

Technical Field

[0001] The present disclosure is directed to multifunctional integral structural heat plates, such as, but not necessarily limited to, heat plate systems configured for supporting battery cells included as part of a battery pack. Background Art

[0002] The vehicle may include an electric motor for converting electrical power into mechanical power for the purpose of utilizing the mechanical power to perform work, such as mechanically powering a drive train to propel the vehicle. Such a vehicle may include a battery pack for storing and supplying electrical power for the electric motor, wherein the battery pack typically includes some form of battery housing for encapsulating a plurality of battery cells, typically arranged to form one or more battery modules. In the past, battery housings have included multi-piece, segmented, or non-integral constructions whereby battery trays may be welded, fixed, or otherwise attached to a plurality of dividers for the purpose of supporting rows or groups of battery cells. Such multi-piece constructions may be disadvantageous because the welding process required to connect the trays, dividers, and optional additional components typically requires larger sized components to accommodate the welding material, a labor-intensive and time-consuming process of individually welding each component together, and the welds often have limited ability to maximally seal the battery cells from each other and / or from the external environment. Summary of the invention

[0003] One non-limiting aspect of the present disclosure relates to a multifunctional integral structural heat plate system for supporting a plurality of battery cells included as part of a high voltage battery pack. The heat plate system may include an integral, one-piece structure operable to thermally conduct heat away from the battery cells and physically support the battery cells. The integral, one-piece structure may include a base plate and a plurality of cross beams formed as part of an extrusion process such that the base plate and cross beams may be integrally formed without the need for welding or other labor-intensive and time-consuming processes to provide, and wherein the integral, one-piece structure effectively and maximally seals a lower portion of a battery channel between the cross beams so as to at least partially seal the battery cells from each other and / or from an external environment.

[0004] One non-limiting aspect of the present disclosure relates to a multifunctional integral structural thermal plate system for supporting a plurality of battery cells included as part of a high voltage battery pack. The system may include a base plate configured to support a bottom surface of one or more of the battery cells, wherein the base plate is formed relative to a longitudinal axis, a width axis, and a height axis. The system may also include a plurality of cross beams configured to support the sides of one or more of the battery cells, wherein the cross beams are intermittently spaced along an upper surface of the base plate relative to the longitudinal axis and are formed to protrude across the upper surface in a width direction relative to the width axis and protrude upward from the upper surface in a height direction relative to the height axis. The base plate and the cross beams may together form an integral, one-piece structure operable to thermally conduct heat away from the battery cells and physically support the battery cells.

[0005] The bottom plate may include a plurality of apertures formed within the interior cavity below the upper surface, wherein the apertures are operable to circulate a coolant to facilitate thermal conduction of heat away from the battery cells.

[0006] The system may include a plurality of spring clips disposed between corresponding ones of the beams and the battery cells, wherein the spring clips are configured to resiliently press against corresponding ones of the battery cells.

[0007] The spring clips may be configured to pre-compress the battery cell during installation and to accommodate battery cell expansion during maintenance.

[0008] The spring clip may include a convex shape configured to flatten in response to expansion of the battery cell corresponding thereto.

[0009] The system may include a thermally conductive material applied to the cross-member, wherein the thermally conductive material is operable to facilitate heat transfer between the thermally enhanced battery cells and the cross-member.

[0010] The beam may include a substantially planar shape, a wavy shape, and / or an hourglass shape.

[0011] The system may include that one or more opposing longitudinal ends of the base plate may be shaped to include an interlock operable to connect with an interlock of another base plate or a side wall of the battery tray.

[0012] The system may include a pair of side walls adhered to opposing lateral sides of the floor and corresponding ones of the beams, wherein the side walls define a battery cell channel between adjacent ones of the corresponding beams.

[0013] The side walls may be adhered to the cross beams and the floor such that a lower portion of each battery cell channel is sealed relative to a lower portion of an adjacent battery cell channel.

[0014] The sidewall may include a plurality of through holes aligned with the plurality of holes formed in the interior cavity of the bottom plate.

[0015] The system acc may include a cold plate configured to support the bottom plate and the lower surfaces of the side walls.

[0016] The unitary, one-piece structure may be formed as part of the extrusion process.

[0017] One non-limiting aspect of the present disclosure is directed to a battery pack for a vehicle. The battery pack may include: an integral multifunctional one-piece structural thermal plate having a plurality of cross beams intermittently spaced along a floor, wherein the cross beams are shaped to extend across the floor in a width direction and upwardly away from the floor; and a plurality of battery cells disposed between the cross beams such that the bottoms of the battery cells are supported on the floor and opposite sides of the battery cells are supported by adjacent pairs of cross beams.

[0018] The battery pack may include a plurality of spring clips disposed between the crossbar and the battery cells, wherein the spring clips have a convex shape configured to elastically press against corresponding ones of the battery cells such that the spring clips pre-compress the battery cells during installation and accommodate expansion of the battery cells during maintenance.

[0019] The bottom plate may include a plurality of apertures formed within the interior cavity, wherein the apertures are operable to circulate a coolant to facilitate thermal conduction of heat away from the battery cells.

[0020] One non-limiting aspect of the present disclosure relates to a vehicle. The vehicle may include an integral multifunctional one-piece structural thermal panel having a plurality of cross beams intermittently spaced along a floor, wherein the cross beams are shaped to extend across the floor in a width direction and upwardly away from the floor. The vehicle may also include a plurality of battery cells configured to store and supply electrical power, wherein the battery cells are disposed between the cross beams such that the bottom of the battery cells is supported on the floor and opposite sides of the battery are supported by adjacent pairs of cross beams. The vehicle may also include an electric motor operable to generate mechanical power suitable for propelling the vehicle in response to electrical power provided from the battery cells.

[0021] The vehicle may include a plurality of spring clips disposed between the cross beam and the battery cells, wherein the spring clips have a convex shape configured to resiliently press against corresponding ones of the battery cells such that the spring clips pre-compress the battery cells during installation and accommodate expansion of the battery cells during maintenance.

[0022] The vehicle may include a thermally conductive material applied to the cross-member, wherein the thermally conductive material is operable to facilitate heat transfer between the thermally enhanced battery cells and the cross-member.

[0023] The vehicle may include a coolant system configured to circulate a coolant through a plurality of holes formed within an interior cavity of the floor pan, wherein the coolant system includes a cold plate disposed relative to the floor pan to facilitate removal of heat from the floor pan.

[0024] Solution 1. A multifunctional integrated structural thermal plate system for supporting a plurality of battery cells included as part of a high voltage battery pack, comprising:

[0025] a bottom plate configured to support a bottom surface of one or more of the battery cells, wherein the bottom plate is shaped relative to a longitudinal axis, a width axis, and a height axis;

[0026] a plurality of cross beams configured to support sides of one or more of the battery cells, wherein the cross beams are intermittently spaced along the upper surface of the floor relative to the longitudinal axis and are shaped to protrude across the upper surface in a width direction relative to the width axis and to protrude upward from the upper surface in a height direction relative to the height axis; and

[0027] Therein, the floor and cross beams together form an integral, one-piece structure operable to thermally conduct heat away from the battery cells and to physically support the battery cells.

[0028] Option 2. The hot plate system according to Option 1, wherein:

[0029] The bottom plate includes a plurality of apertures formed within the interior cavity below the upper surface, wherein the apertures are operable to circulate a coolant to facilitate thermal conduction of heat away from the battery cells.

[0030] Solution 3. The hot plate system according to Solution 1 further includes:

[0031] A plurality of spring clips are disposed between corresponding ones of the beams and the battery cells, the spring clips being configured to elastically press against corresponding ones of the battery cells.

[0032] Option 4. The hot plate system according to Option 3, wherein:

[0033] The spring clips are configured to pre-compress the battery cell during installation and to accommodate cell expansion during maintenance.

[0034] Option 5. The hot plate system according to Option 4, wherein:

[0035] The spring clip has a convex shape configured to flatten in response to expansion of the battery cell to which it corresponds.

[0036] Solution 6. The hot plate system according to Solution 1, further comprising:

[0037] A thermally conductive material applied to the cross-member, the thermally conductive material being operable to facilitate heat transfer between the thermally enhanced battery cells and the cross-member.

[0038] Option 7. The hot plate system according to Option 1, wherein:

[0039] The beam has a substantially planar shape.

[0040] Option 8. The hot plate system according to Option 1, wherein:

[0041] The cross beam has a substantially wavy shape.

[0042] Option 9. The hot plate system according to Option 1, wherein:

[0043] The beam has a substantially hourglass shape.

[0044] Option 10. The hot plate system according to Option 1, wherein:

[0045] One or more opposing longitudinal ends of the base plate are shaped to include interlocks operable to connect with interlocks of another base plate or a side wall of the battery tray.

[0046] Solution 11. The hot plate system according to Solution 1, further comprising:

[0047] A pair of side walls are adhered to opposite lateral sides of the floor and corresponding ones of the beams, the side walls defining a battery cell channel between adjacent ones of the corresponding beams.

[0048] Embodiment 12. The hot plate system according to embodiment 11, wherein:

[0049] The side walls are adhered to the cross beams and the floor such that a lower portion of each battery cell channel is sealed relative to a lower portion of an adjacent battery cell channel.

[0050] Embodiment 13. The hot plate system according to embodiment 12, wherein:

[0051] The sidewall includes a plurality of through holes aligned with the plurality of holes formed in the interior cavity of the bottom plate.

[0052] Solution 14. The hot plate system according to Solution 11, further comprising:

[0053] A cold plate is configured to support the bottom surface of the bottom plate and the side walls.

[0054] Embodiment 15. The hot plate system according to embodiment 1, wherein:

[0055] The unitary, one-piece structure is formed as part of the extrusion process.

[0056] Solution 16. A battery pack for a vehicle, comprising:

[0057] an integral multifunctional one-piece structural thermal panel having a plurality of beams intermittently spaced along a base plate, the beams being shaped to extend across the base plate in a width direction and upwardly away from the base plate; and

[0058] A plurality of battery cells are disposed between the cross beams such that the bottoms of the battery cells are supported on the floor and opposing sides of the cells are supported by adjacent pairs of cross beams.

[0059] Solution 17. The battery pack according to Solution 16 further comprises:

[0060] A plurality of spring clips are disposed between the crossbar and the battery cells, the spring clips having a convex shape configured to resiliently press against corresponding ones of the battery cells such that the spring clips pre-compress the battery cells during installation and accommodate expansion of the battery cells during maintenance.

[0061] Option 18. The battery pack according to Option 17, wherein:

[0062] The bottom plate includes a plurality of apertures formed within the interior cavity, wherein the apertures are operable to circulate a coolant to facilitate thermal conduction of heat away from the battery cells.

[0063] Solution 19. A vehicle, comprising:

[0064] an integral multifunctional one-piece structural thermal panel having a plurality of beams intermittently spaced along a base plate, the beams being shaped to extend across the base plate in a width direction and upwardly away from the base plate;

[0065] a plurality of battery cells configured to store and supply electrical power, wherein the battery cells are disposed between the beams such that the bottoms of the battery cells are supported on the floor and opposing sides of the battery cells are supported by adjacent pairs of beams; and

[0066] An electric motor is operable to generate mechanical power suitable for propelling the vehicle in response to electrical power provided from the battery unit.

[0067] Solution 20. The vehicle according to Solution 19, further comprising:

[0068] a plurality of spring clips disposed between the crossbar and the battery cells, the spring clips having a convex shape configured to resiliently press against corresponding ones of the battery cells such that the spring clips pre-compress the battery cells during installation and accommodate expansion of the battery cells during maintenance;

[0069] a thermally conductive material applied to the crossbar, the thermally conductive material operable to facilitate heat transfer between the thermally enhanced battery cells and the crossbar; and

[0070] A coolant system is configured to circulate a coolant through a plurality of holes formed in the interior cavity of the base plate, wherein the coolant system includes a cold plate disposed relative to the base plate to facilitate heat removal from the base plate.

[0071] The above-mentioned features and advantages of the present teaching and other features and advantages may be readily apparent through the following detailed description of the mode for implementing the present teaching in conjunction with the accompanying drawings. It should be understood that, although the following drawings and embodiments may be described separately, their individual features may also be combined into additional embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The accompanying drawings, which may be incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0073] Figure 1 A schematic diagram of a vehicle according to one non-limiting aspect of the present disclosure is shown.

[0074] Figure 2 A partially assembled view of a battery pack according to one non-limiting aspect of the present disclosure is shown.

[0075] Figure 3 A partial side view of a multifunctional unitary structural thermal panel according to one non-limiting aspect of the present disclosure is shown.

[0076] Figure 4 A partial side view of a battery cell disposed within a multifunctional integral structural thermal plate is shown according to one non-limiting aspect of the present disclosure.

[0077] Figure 5 A partial perspective view of a multifunctional integral structural thermal panel according to one non-limiting aspect of the present disclosure is shown.

[0078] Figure 6 A partial perspective view of a battery cell disposed within a multifunctional integral structural thermal plate is shown according to one non-limiting aspect of the present disclosure.

[0079] Figure 7 A partial perspective view of a segmented multi-functional unitary structural thermal panel is shown in accordance with one non-limiting aspect of the present disclosure.

[0080] Figure 8 A partial perspective view of a multifunctional integral structural thermal panel having corrugated cross beams according to one non-limiting aspect of the present disclosure is shown. DETAILED DESCRIPTION

[0081] As desired, detailed embodiments of the present disclosure may be disclosed herein; however, it is understood that the disclosed embodiments may be merely examples of the present disclosure that may be implemented in various and alternative forms. The drawings may not necessarily be drawn to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein may not need to be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to use the present disclosure in various ways.

[0082] Figure 1 A schematic diagram of a vehicle 10 according to one non-limiting aspect of the present disclosure is shown. The vehicle 10, which may be interchangeably referred to as an electric or hybrid vehicle 10, may include an electric motor 12 operable to convert electrical power into mechanical power for the purpose of utilizing the mechanical power to perform work, such as mechanically powering a drive system to propel the vehicle. The vehicle 10 is shown as a hybrid type because the powertrain 16 optionally includes an internal combustion engine (ICE) 18 for generating mechanical power. The powertrain 16 may include a transmission, a drive shaft, a differential, an axle, and / or other components to facilitate the transfer of rotational force from a rotor shaft coupled to a rotor to one or more of wheels 20, 22, 24, 26. The vehicle 10 may include a battery pack 30 for storing and supplying electrical power to the electric motor 12 and / or other systems, buses, etc. on the vehicle 10. The vehicle 10 may include a battery monitoring system or controller 32 to facilitate monitoring, controlling, measuring, and otherwise directing the operation, performance, etc. of the battery pack 30. The battery pack 30 may be mounted or secured to a chassis or other structure within the vehicle 10, with one common implementation including positioning the battery pack 30 beneath the floor and being shaped and sized so that the battery pack 30 extends fore and aft relative to the front and rear of the vehicle and laterally from the driver's side to the passenger side.

[0083] Figure 2An assembly diagram of a battery pack 30 according to one non-limiting aspect of the present disclosure is shown. The battery pack 30 may include a cover 36, a plurality of battery cells 38, a multi-functional integrated structural thermal (MUST) plate system 40, and a cooling system 42. In addition to or in lieu of those described herein, the present disclosure contemplates that the battery pack 30 includes a wide variety of components to facilitate placement and use within the vehicle 10 and / or within other types of devices other than a vehicle. The various components of the battery pack 30 described herein are non-limiting and are intended to represent only the types of battery packs 30 that may benefit from incorporation of the MUST plate system 40. In other words, the components presented as cooperating with the MUST plate system 40 are merely illustrative of items, components, modules, etc. that may cooperate with the MUST plate system 40, and are not intended to limit the scope and contemplation of the present disclosure. The MUST plate system 40, interchangeably referred to as the thermal plate system 40, may include an integral, one-piece structure operable to thermally conduct heat away from the battery cells 38 and physically support the battery cells 38.

[0084] The unitary, one-piece structure may include a base plate 48 and a plurality of cross beams 50 formed as part of an extrusion process such that the base plate 48 and cross beams 50 may be integrally formed without the need for welding or other labor-intensive and time-consuming processes to provide, and wherein the unitary, one-piece structure effectively and maximally seals at least the lower portion between the cross beams 50 to at least partially seal the battery cells 38 from each other and / or from the external environment. The base plate 48 and cross beams 50 may be formed in an integral manner without the need for welding or other labor-intensive and time-consuming processes to provide, and wherein the unitary, one-piece structure effectively and maximally seals at least the lower portion between the cross beams 50 to at least partially seal the battery cells 38 from each other and / or from the external environment. Figure 3 , which shows a side view of a portion of a MUST plate system 40 according to one non-limiting aspect of the present disclosure. As also shown, the MUST plate system 40 can alternatively or additionally include a plurality of spring clips 52 attached to the crossbar 50. The spring clips 52 can be disposed between the crossbar 50 and corresponding ones of the battery cells 38 and configured to resiliently press against corresponding ones of the battery cells 38. The spring clips 52 can be configured to pre-compress the battery cells 38 during installation and accommodate expansion of the battery cells 38 during maintenance, optionally with the spring clips 52 having a convex shape configured to flatten in response to expansion of the battery cells 38. The flattening of the spring clips 52 can be performed during installation. Figure 4 , which shows a side view of a portion of the MUST panel system 40 with the battery cells 38 inserted into corresponding battery channels 56 defined between the cross-members 50 .

[0085] The bottom plate 48 may be shaped relative to the longitudinal axis, the width axis, and the height axis such that the bottom plate 48 includes an upper surface, a lower surface, a front surface, a rear surface, and opposing lateral side surfaces. Figure 5As shown in , the cross beams 50 can have a planar shape and be intermittently spaced along the upper surface of the bottom plate 48 relative to the longitudinal axis and are shaped to protrude across the upper surface in the width direction relative to the width axis and protrude upward from the upper surface in the height direction relative to the height axis. The bottom plate 48 and the cross beams 50 together can form an integral, one-piece structure contemplated herein for thermally conducting heat away from the battery cells 38 and physically supporting the battery cells 38. Figure 6 As shown in , the bottom plate 48 can be configured to support the bottom surface of one or more of the battery cells 38. The cross beams 50 can be configured to support the sides of one or more of the battery cells 38 placed in the battery channel 56 associated therewith. The cross beams 50 can extend across the entire bottom plate 48 in the width direction, so that each cross beam 50 extends from one lateral side to an opposite lateral side, which can be used to seal the battery cells 38 in one battery channel 56 with the battery cells 38 in the adjacent battery channel 56.

[0086] However, the present disclosure fully contemplates that the crossbars 50 extend in the width direction in different ways, such as by partially extending across the bottom plate 48 in the width direction and / or in different directions, for example, one or more crossbars 50 can be perpendicular to the crossbars 50 shown to extend from the front surface to the rear surface in the longitudinal direction along the upper surface. Likewise, the crossbars 50 can extend in the height direction in the manner shown so that a portion thereof extends above the battery cells 38, which can be used to facilitate the attachment of the cover 36 and / or further maximize the ceiling of one battery channel 56 from another battery channel. This is shown for non-limiting purposes, as the present disclosure fully contemplates crossbars 50 with other heights, including some crossbars 50 having different heights relative to other crossbars 50 and / or the same crossbar 50 having a corrugation or other height difference from one end to the other. The crossbars 50 can correspond to a wide range of various shapes and configurations that can be extruded or otherwise formed as a unitary structure with the bottom plate 48. Thermally conductive material 60 can be optionally applied to the crossbars 50 to facilitate thermally enhanced heat transfer between the battery cells 38 and the crossbars 50. The floor 48 may be constructed in a variety of configurations, shapes, sizes, etc., optionally with portions of the floor 48 having different sizes to accommodate placement within the vehicle 10 and / or other dimensional constraints and requirements.

[0087] The battery cells 38 supported by the MUST plate system 40 are shown as prismatic battery cells 38, which can be manufactured to include flat, rectangular or square shapes, enclosed in aluminum, steel, plastic or laminated bags or composite housings. However, the battery cells 38 can be shaped differently, including battery cells 38 in the shape or type of bags or cans with rigid or semi-rigid and in some cases flexible housings. In particular, when the vehicle 10 is propelled only by the electric motor 12, the battery pack 30 may include battery cells 38 arranged in a plurality of battery modules, optionally, the modules and / or battery cells 38 are connected in series and / or in parallel with each other. The battery pack 30 may include battery cells 38 composed of a wide range of various materials operable to facilitate storage and supply of electrical power, and therefore, the present disclosure is not intended to be limited to specific battery materials, chemistries, etc. The battery cells 38 shown may have substantially uniform shapes and sizes, so that the shapes and sizes of the crossbars 50 may be correspondingly uniform, however, the crossbars 50 may be correspondingly varied to accommodate different sizes, shapes, configurations, etc. of the battery cells 38.

[0088] Back to Figure 2 , the MUST plate system 40 may be customized to cooperate with a cooling system 42, which may include a cold plate 64, a plurality of conduits 66, a pump and coolant element (not shown) operable to facilitate thermal conduction of heat away from the battery cells 38 via a coolant pumped through the conduits 66 relative to the base plate 48. The cold plate 64 is non-purposely shown as being adhered to or otherwise in physical contact with the lower surface of the base plate 48, such as by brazing. Additional cold plates may be included, such as above the battery cells 38, optionally in place of the cover 36, and / or multiple cold plates may be employed. As shown Figure 3 As shown in more detail in , the bottom plate 48 may optionally include a plurality of holes 70 formed within the interior cavity below the upper surface. The holes 70 may extend throughout the interior cavity to facilitate circulation of coolant therethrough for the purpose of thermally conducting heat away from the battery cells 38. The bottom plate 48 may alternatively be formed without the holes 70 as a solid piece of material, and optionally, the conduits 66 are instead configured to circulate coolant through the cold plate 64. The MUST plate system 40 or cooling system 42 may include a pair of side walls 72, 74 that are adhered to opposing lateral sides of the bottom plate 48 and corresponding ones of the crossbars 50. The side walls 72, 74 may be used to seal the ends of the battery channels 56 so that the lower portion of each battery cell 38 channel 56 is sealed relative to the lower portion of the adjacent battery cell 38 channel 56. The side walls 72, 74 may include a plurality of through holes 76 that align with the holes 70 formed within the interior cavity of the bottom plate 48 to provide an opening for the conduits 66 to establish a fluid connection with the holes 70.

[0089] The holes 70 are shown extending substantially along a similar path as corresponding ones of the beams 50, with the holes optionally extending widthwise across the bottom plate 48 in an area below the corresponding beam 50. Figure 5 As shown in , the bottom plate 48 may also include interlocks 78, 80 at one or more of the front and rear surfaces (i.e., at opposite longitudinal ends of the bottom). The interlocks 78, 80 are operable to connect with interlocks of a side wall of another bottom plate 48 or a battery tray (not shown). Figure 7 As shown in , the bottom plate 48 can be divided into segments 84, such as in the manner shown, where one segment 84 is associated with each cross member 50, wherein the front and rear surfaces are shaped to include corresponding portions of the interlocking devices 78, 80. The interlocking devices 78, 80 can be shaped in a tongue-and-groove manner as shown to facilitate connecting the portions of the bottom plate 48 together, however, other shapes and configurations can be used without departing from the scope and contemplation of the present disclosure. Figure 5 The embodiment shown in FIG. 4 may be advantageous from an assembly and manufacturing perspective because the base plate 48 is larger and therefore requires fewer interlocking devices 78, 80, and Figure 7 The embodiment shown in FIG. 5 may be advantageous from an extrusion process perspective because the extrusion of the smaller sections 84 of the base plate 48 and cross beam 50 is less complicated.

[0090] The above-described embodiments generally involve battery cells 38 being somewhat rectangular in shape so that the battery cells 38 may be dropped or loaded vertically into the battery channel 56 , ie, by pressing the battery cells 38 into the battery channel 56 from top to bottom relative to the crossbar 50 . Figure 8 A crossbar 50 having a wavy or hourglass shape is shown according to one non-limiting aspect of the present disclosure. The crossbar 50 can be shaped in the manner shown to accommodate battery cells 38 having a substantially cylindrical shape. The cylindrical battery cells 38 can be inserted or loaded into the battery channel 56 horizontally or laterally, i.e., by pressing the battery cells 38 into the battery channel 56 from one side to the other relative to the crossbar 50. The wavy / hourglass shape can be provided in the manner shown to include narrower portions between vertically spaced rows of battery cells 38. The ability to offset and separate rows of battery cells 38 from each other using the crossbar 50 can be beneficial in facilitating electrical interconnection therebetween and / or providing a path for air and / or other coolant to pass between the vertically spaced battery cells 38.

[0091] Although various embodiments have been described, the description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the embodiments. Unless specifically limited, any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. In addition, various modifications and changes may be made within the scope of the appended claims. Although several modes for implementing many aspects of this teaching have been described in detail, those skilled in the art to which this teaching belongs will recognize various alternative aspects for practicing this teaching within the scope of the appended claims. All of the content contained in the above description or shown in the accompanying drawings should be intended to be understood as an illustration and example of the entire scope of alternative embodiments, and those of ordinary skill in the art will recognize the alternative embodiments by structurally and / or functionally equivalent implications or become apparent in other ways based on the included content, rather than being limited to those embodiments that are explicitly depicted and / or described.

Claims

1. A multifunctional integrated structural thermal plate system for supporting a plurality of battery cells included as part of a high voltage battery pack, comprising: a bottom plate configured to support a bottom surface of one or more of the battery cells, wherein the bottom plate is shaped relative to a longitudinal axis, a width axis, and a height axis; a plurality of cross beams configured to support sides of one or more of the battery cells, wherein the cross beams are intermittently spaced along the upper surface of the floor relative to the longitudinal axis and are shaped to protrude across the upper surface in a width direction relative to the width axis and to protrude upward from the upper surface in a height direction relative to the height axis; and Therein, the floor and cross beams together form an integral, one-piece structure operable to thermally conduct heat away from the battery cells and to physically support the battery cells.

2. The hot plate system according to claim 1, wherein: The bottom plate includes a plurality of apertures formed within the interior cavity below the upper surface, wherein the apertures are operable to circulate a coolant to facilitate thermal conduction of heat away from the battery cells.

3. The hot plate system according to claim 1, further comprising: A plurality of spring clips are disposed between corresponding ones of the beams and the battery cells, the spring clips being configured to elastically press against corresponding ones of the battery cells.

4. The hot plate system according to claim 3, wherein: The spring clips are configured to pre-compress the battery cell during installation and to accommodate cell expansion during maintenance.

5. The hot plate system according to claim 4, wherein: The spring clip has a convex shape configured to flatten in response to expansion of the battery cell to which it corresponds.

6. The hot plate system according to claim 1, further comprising: A thermally conductive material applied to the cross-member, the thermally conductive material being operable to facilitate heat transfer between the thermally enhanced battery cells and the cross-member.

7. The hot plate system of claim 1, wherein: The beam has a substantially planar shape.

8. The hot plate system of claim 1, wherein: The cross beam has a substantially wave-shaped shape.

9. The hot plate system of claim 1, wherein: The beam has a substantially hourglass shape.

10. The hot plate system of claim 1, wherein: One or more opposing longitudinal ends of the base plate are shaped to include interlocks operable to connect with interlocks of another base plate or a side wall of the battery tray.

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