Thermally conductive polymer cooling plate for battery thermal management

Abstract

A cooling plate for battery thermal management in a battery pack and a process of forming such a battery pack are provided. The cooling plate is made of a composite material, and the cooling plate is of a hollow structure. The composite material comprises a heat-conducting filler, and the heat-conducting filler is dispersed in a polymer matrix. The hollow structure has an outer wall having a thickness in a range of about 0.3 mm (mm) to about 2.5 mm. The hollow structure comprises a top section, a bottom section and one or more channels, and the top section is in thermal contact with the at least one battery; the bottom section and the top section are integrally formed; one or more channels are located between the top section and the bottom section, the one or more channels configured to allow fluid flow through the one or more channels to provide thermal management of the battery.

Description

Technical Field

[0001] The present invention relates to a cooling plate for providing thermal management for a battery or a battery module and / or a battery pack. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and definitions of certain terms used in the present disclosure and may not constitute prior art.

[0003] Currently, in electric vehicles (EV) or hybrid electric vehicles (HEV), aluminum plates are commonly used to provide heat transfer for battery packs. The cooling plate is typically located at the bottom of the battery pack, which typically houses multiple batteries or battery modules. The cooling plate allows a fluid to circulate therein for heat transfer. Examples of commonly used fluid types include water or water / ethylene glycol mixtures. Since the aluminum plate is conductive, some form of polymer pad or adhesive layer is typically provided between the batteries in the battery pack and the cooling plate. Therefore, the pad is in physical contact with both the battery and the cooling plate. The use of the pad also helps to eliminate any air gaps that exist due to assembly tolerances and the roughness of the outer surface of the battery and the outer surface of the cooling plate. The pad or adhesive layer combined with the aluminum plate may have a negative impact on the cost, assembly, recycling and weight of the battery pack / cooling plate combination.

[0004] Another type of cooling plate can be formed using a film or composite foil as a flexible top layer combined with a rigid lower plate. The film or composite foil has a very thin cross section with a cross-sectional thickness of about 100 microns or less. As the fluid circulates in the composite foil, the composite foil expands, similar to a balloon. All contact forces applied to the battery are achieved via this expansion technology. However, because the thin cross section of the expandable membrane is limited in thermal conductivity and is susceptible to tearing, the performance and life of this type of cooling plate remain to be determined. In addition, the film or composite foil may not be able to withstand the weight or dynamic forces applied by the battery that the film or foil attempts to support. Summary of the invention

[0005] The object of the present disclosure is to overcome the above disadvantages and provide an improved cooling plate for thermal management of a battery or battery pack. In this regard, the present disclosure generally includes a cooling plate for thermal management of a battery. The cooling plate includes a composite material, the cooling plate is formed in the shape of a hollow structure, the hollow structure has an outer wall, and the thickness of the outer wall is in the range of about 0.3 mm (millimeter) to about 2.5 mm. The components of the composite material include a thermally conductive filler dispersed in a polymer matrix. When desired, the thermally conductive filler can also exhibit a low degree of electrical conductivity. The hollow structure includes a top section, a bottom section, and one or more channels, the top section is in thermal contact with at least one battery; the bottom section is integrally formed with the top section; and the one or more channels are located between the top section and the bottom section. The one or more channels are configured to allow a fluid to flow through the one or more channels to provide thermal management of the battery. The composite material is incorporated into the hollow structure so that the volume change of the hollow structure is less than about 15% when the fluid is allowed to flow through the one or more channels. When desired, the hollow structure can be formed as a single component.

[0006] The thermally conductive filler comprises a plurality of particles, the components of which are selected from the group consisting of boron nitride, aluminum oxide, aluminum nitride, silicon nitride, silicon carbide, graphene, carbon nanotubes, or mixtures thereof. The polymer matrix is ​​an elastomer, a thermoplastic material, or a thermoplastic elastomer (TPE), the Shore A hardness of which is in the range of about 40 to 100, or the Shore D hardness of which is in the range of about 20 to about 75. Alternatively, the components of the composite material comprise a plurality of boron nitride particles dispersed in a thermoplastic elastomer (TPE), the Shore A hardness of which is in the range of about 70 to about 80. The thermally conductive filler accounts for between about 5 wt.% and about 25 wt.% of the total weight of the composite material.

[0007] According to one aspect of the present disclosure, one or more channels in the hollow structure may include a structural element configured to support the weight of the battery. The composition of the structural element may be different from the composition of the cooling plate. In addition, when desired, at least one of the bottom section and the top section may include one or more features configured to increase stiffness and promote fluid mixing by directing fluid flow. These features may protrude from the top section, the bottom section, or both the top section and the bottom section into the one or more channels.

[0008] The top section of the cooling plate may be flat to maintain at least 50% surface contact with the battery.The top section may also include one or more bumper stops configured to assist in placement and retention of the battery.

[0009] According to another aspect of the present disclosure, a battery pack with thermal management is provided. The battery pack comprises: at least one battery; and a cooling plate as previously described above and as further defined herein, the cooling plate comprising a composite material, the cooling plate being formed into the shape of a hollow structure.

[0010] According to another aspect of the present disclosure, a cooling plate may be used to provide thermal management for at least one battery in an electric vehicle (EV) or a hybrid electric vehicle (HEV).

[0011] According to another aspect of the present disclosure, a process for forming a battery pack configured for thermal management is provided. The process includes: providing a composite material; performing a molding process on the composite material to form a hollow structure; providing at least one battery; assembling the at least one battery with the hollow structure so that the battery is in thermal contact with a top section of the hollow structure; and allowing a fluid to flow through one or more channels located within the hollow structure. When a molding process is used, the process can be selected from one of the group consisting of: blow molding, injection molding, compression molding, rotational molding, or a combination of the above processes.

[0012] When desired, the process may also include forming one or more structural elements in at least one channel of the hollow structure to assist in supporting the weight of the battery or battery module. These structural elements may be formed by a molding process, such as blow molding using a "ship in a bottle" technique, for example.

[0013] When desired, the process may also include forming one or more features that protrude from the top segment, the bottom segment, or both into the one or more channels to increase stiffness and promote fluid mixing by directing fluid flow.

[0014] Further areas of applicability will become apparent from the description provided herein.It should be understood that the 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

[0015] In order to better understand the present disclosure, the present disclosure will now be described in its various forms by way of example with reference to the accompanying drawings. The components in each drawing are not necessarily drawn to scale, emphasis instead being placed upon illustrating the principles of the present invention.

[0016] Figure 1 is a schematic illustration showing a peripheral view of a battery pack incorporating a cooling plate formed in accordance with the teachings of the present disclosure.

[0017] Figure 2A yes Figure 1 A cross-sectional view of a battery pack taken along axis x, wherein the hollow structure of the cooling plate is depicted in more detail.

[0018] Figure 2B is with Figure 2A A cross-sectional view of another battery pack similar to the one shown, depicting an alternative configuration of the cooling plate.

[0019] Figure 3 yes Figure 2B A cross-sectional view of a battery pack in which structural elements are formed in one or more channels according to the teachings of the present disclosure.

[0020] Figure 4 yes Figure 1 The three-dimensional exploded view of the battery pack Figure 4 Shown are features that include protrusions into one or more channels of a cooling plate in accordance with the teachings of the present disclosure.

[0021] Figure 5 yes Figure 4 A perspective view of a bottom section of a cooling plate highlighting a prominent feature in which fluid flows through one or more channels.

[0022] Figure 6 is a schematic diagram showing the use of composite materials to form a top section, a bottom section, and sides connecting the top section and the bottom section in accordance with the teachings of the present disclosure.

[0023] Figure 7 is a flow chart of a process for forming a battery pack according to the teachings of the present disclosure.

[0024] The drawings provided herein are for illustration purposes only and are not intended to limit the scope of the present invention. DETAILED DESCRIPTION

[0025] The following description is merely exemplary in nature and is in no way intended to limit the present disclosure or its application or use in any way. For example, throughout the present disclosure, cooling plates manufactured and used in accordance with the teachings contained herein are described in conjunction with thermal management of batteries or battery packs in electric vehicles (EVs) or hybrid electric vehicles (HEVs) to more fully illustrate the structural elements and their use. In other applications, including but not limited to other electrical devices or apparatuses using batteries or battery packs, the combination and use of such cooling plates are considered to be within the scope of the present disclosure. It should be understood that throughout the specification and drawings, corresponding reference numerals indicate similar or corresponding parts and features.

[0026] As used herein, a "battery cell" refers to the basic electrochemical unit of a battery, which includes an anode and a cathode, and any components for converting the stored chemical energy into electrical energy, such as electrodes, separators, and electrolytes. In contrast, a "battery" or "battery module" refers to at least one battery cell placed in a housing with electrical connections and possible electronics for control and protection. A "battery pack" refers to an assembly of multiple batteries, in other words, a plurality of battery modules connected in series or in parallel to each other to increase the voltage or capacity, the voltage or capacity increase resulting from the series connection or parallel connection, wherein the assembly of batteries is fixed in the housing.

[0027] In this specification, the embodiments have been described in a manner that allows for a clear and concise description to be written, but it is intended and should be understood that the embodiments can be combined or separated in various ways without departing from the present invention. For example, it should be understood that all preferred features described herein are applicable to all aspects of the present invention described herein.

[0028] The present disclosure provides a cooling plate for thermal management of batteries. The cooling plate generally includes a composite material, the components of the composite material include a thermally conductive filler, the thermally conductive filler is dispersed in a polymer matrix, and the cooling plate is formed in the shape of a hollow structure. The hollow structure includes a top section, a bottom section, and one or more channels between the top section and the bottom section. At least one of the top section or the bottom section of the hollow structure is in thermal contact with at least one battery. In other words, the cooling plate is in thermal contact with a portion of the battery, such as a top portion, a bottom portion, or a side portion of a battery module. The bottom section is formed integrally with the top section. One or more channels are configured to allow a fluid to flow through the one or more channels to provide thermal management of the battery.

[0029] A cooling plate formed according to the present disclosure and including a composite material provides good thermal conductivity between a battery or battery pack and a heat transfer fluid circulating through the cooling plate. A polymer matrix in which a thermally conductive filler is dispersed in a polymer matrix is ​​used to form a cooling plate, providing a relatively soft and flexible composite material that allows effective heat transfer and does not require the use of a polymer pad or adhesive layer. In this regard, the thermally conductive filler provides good thermal conductivity, while the polymer matrix is ​​soft and flexible enough to directly eliminate the gap between the cooling plate and the battery or battery pack and provide good physical contact between the cooling plate and the battery or battery pack. In addition, when allowing fluid to flow through one or more channels in the cooling plate, the volume change of the composite material used to form the hollow structure may be 20% or less; alternatively, less than 15%; alternatively, about 10% or less; alternatively, not more than 5%. Because the thermally conductive filler can also exhibit low electrical conductivity, the use of the composite material can also effectively provide electrical insulation of the battery pack.

[0030] Although the cooling plates of the present disclosure are not as thermally conductive as conventional commercial aluminum cooling plates, the thermal conductivity provided by the composite material is able to provide the necessary or desired performance for thermal management of the battery pack. In addition, cooling plates including composite materials formed in accordance with the teachings of the present disclosure have the following additional advantages over conventional cooling plates: lower manufacturing costs, lighter weight, easier assembly, reduced likelihood of short circuits within the battery pack, and easier recycling in some cases (e.g., compared to adhesive-based options). The process of forming the cooling plates provides commercial viability for the production of products for small volume markets because the process of forming the cooling plates requires a lower investment cost than the manufacturing process associated with conventional cooling plates, which investment cost is primarily derived from differences in tooling.

[0031] For purposes of the present disclosure, the terms "about" and "substantially" as used herein with respect to measurable values ​​and ranges refer to expected variations known to those skilled in the art (eg, limitations and variability in measurements).

[0032] For the purposes of this disclosure, the terms "at least one" element and "one or more" elements may be used interchangeably and may have the same meaning. These terms may include a single element or multiple elements, and may also be represented by the suffix "(s)" at the end of the element. For example, "at least one channel", "one or more channels" and "channel (s)" may be used interchangeably and are intended to have the same meaning.

[0033] Reference now Figure 1 , the battery pack 1 is shown as having three batteries 5, each of which has a positive terminal 30 (+) and a negative terminal 30 (-), which are located in a housing 10 associated with the battery pack 1. The cooling plate 15 is positioned so that the top section 20 of the cooling plate 15 is in thermal contact with at least one battery 5, alternatively, with all batteries 5 in the battery pack 1. Figure 1 As shown, in order to more fully illustrate the structure of the cooling plate 15 and its use, the cooling plate 15 is depicted in each of the figures herein as being in contact with the bottom of the battery or battery module. However, the cooling plate can be reversed so that the top section 20 of the cooling plate is in contact with the top surface of the battery 5 or battery module 5 without exceeding the scope of the present disclosure. Similarly, when a particular application requires or desires, the cooling plate 15 can be configured so that the top section 20 of the cooling plate is in thermal contact with one or more sides of the battery or battery module in the battery pack.

[0034] The surface of the top section 20 of the cooling plate 15 is generally flat to enhance thermal contact and / or heat exchange with the battery 5. The top section 20 of the cooling plate 15 may also include one or more buffer stops 25 or bosses configured to assist in placing and retaining the battery 5 in the battery pack 1.

[0035] Still reference Figure 1 , using a composite material to form the cooling plate provides sufficient ability for the top section 20 of the cooling plate 15 to conform to the battery 5 and establish contact with the battery 5, thereby overcoming any surface roughness or non-uniformity that may be inherently present. The top section 20 of the cooling plate 15 is capable of maintaining at least 50% surface contact with the battery 5. Alternatively, the surface contact of the cooling plate 15 with the battery 5 is maintained between 50% and 100%; alternatively, greater than 50% and less than 100%; alternatively, between 55% and 95%; alternatively, about 60% to about 90%. For purposes of this disclosure, the term "between" is intended to include the limits specified for the stated range.

[0036] Reference now Figure 2A , showing Figure 1 1 is a cross-sectional view of a battery pack 1 taken along the axis x, wherein the hollow structure of the cooling plate 15 is depicted in more detail. More specifically, in addition to the top section 20 being in thermal contact with the battery 5, the bottom section 35 is integrally formed with the top section 20, and depicts one or more channels 40 through which a fluid 45 flows to provide thermal management of the battery 5. Figure 2A The cooling plate 15 is shown with three channels 40 formed therein, separated by solid structures 50A formed between the channels 40 , which separate the channels 40 and provide structural support to the cooling plate 15 to be able to support the total mass of the battery 5 .

[0037] For purposes of this disclosure, the term "integrally formed" means that the top section 20 and the bottom section 35 are formed or molded as a single component, and / or the top section 20 and the bottom section 35 are joined together using one or more of ultrasonic welding, spin welding, vibration welding, hot plate welding, infrared welding, laser welding, and overmolding processes to form a "leak-free" hollow structure. Alternatively, the cooling plate 15 is formed as a single component. Any process known to those skilled in the art capable of forming a single component from a composite material may be used, such as, but not limited to, injection molding or blow molding.

[0038] The hollow structure of the cooling plate 15 is formed with an outer wall thickness t in the range of about 0.3 mm (millimeter) to about 2.5 mm. Alternatively, the wall thickness t can be in the range of about 0.5 mm to about 2.3 mm; alternatively, in the range of about 1.0 mm to about 2.0 mm. Depending on the structural design and manufacturing parameters for a given application, the wall thickness t of the top section 15, the bottom section 35, and one or more side sections s connecting the top section 15 and the bottom section 35 can be the same or different. For example, the selection of one or more wall thicknesses t can vary depending on the thickness required to provide sufficient rigidity to support the weight of the battery and to maintain the stress level in the cooling plate structure below the yield stress of the composite material used to form the structure.

[0039] Reference now Figure 2B , providing Figure 2A A cross-sectional view of a battery pack 1 similar to the battery pack 1 shown in FIG. 1 , wherein the solid structural support member 50A (see Figure 1 ) is replaced by an angled structural support 50B. Depending on the type of process selected for forming the cooling plate 15 (e.g., blow molding, etc.), such an angled structural support 50B design may be desirable. Use of an angled structural support 50B design creates a small area a between the top section 20 of the cooling plate 15 and the battery 5, where very limited or no heat transfer will occur due to lack of thermal contact. When the overall contact of the top section 20 of the cooling plate 15 with the battery 5 is maintained at 50% or more surface contact as previously discussed herein, the presence of the small area a does not affect the performance of the cooling plate 15 in providing thermal management of the battery 5.

[0040] Reference now Figure 3 , showing a cross-sectional view of a battery pack 1 in which the cooling plate of FIG. 2 is incorporated into a battery pack 1, wherein one or more channels 40 present in the cooling plate 15 include a structural element 55. The one or more structural elements 55 are configured to assist the cooling plate 15 in supporting the weight of the battery 5. The one or more structural elements may be made of the same material as the cooling plate 15, a different material, or a combination of the same material and a different material. Alternatively, the one or more structural elements are made of high-density polyethylene (HDPE). The one or more structural elements may be manufactured as separate components and formed integrally with the cooling plate during the formation of the hollow structure, which is performed in any process suitable for such a purpose, including but not limited to the use of the "ship in a bottle" technique in a blow molding process.

[0041] Reference now Figure 4, provides a perspective view of a battery pack 1 according to another aspect of the present disclosure. The perspective view highlights that the bottom section 35 can be contoured to control flow and provide additional stiffness. In this regard, the bottom section 35 can include one or more features 60 configured to increase stiffness and promote fluid mixing by directing fluid flow. The one or more features 60 are from the bottom section 15 (such as Figure 4 The shape of feature 60 may be any shape, including but not limited to cylindrical, elliptical, or angular. The number of features 60, the shape of features 60, and the location of features 60 are selected so that they provide the desired flow and / or mixing of fluids in one or more channels. Figure 5 , a flow path 65 is schematically shown relative to a feature 60 rising from the bottom section 35 of the cooling plate 15, which flow path 65 is present in the presence of a protrusion to Figure 4 The one or more channels of the cooling plate feature 60 provide fluid mixing. The fluid may include any type of heat transfer liquid, including but not limited to water or a water / ethylene glycol mixture.

[0042] Reference now Figure 6 The top section 15, the bottom section 35, and one or more side sections connecting the bottom section and the top section of the cooling plate generally include a composite material 70. The composite material 70 includes or essentially includes a thermally conductive filler 75, or includes a thermally conductive filler 75, which is dispersed in a polymer matrix 80. The thermally conductive filler 75 can also exhibit a low degree of electrical conductivity to assist in the electrical insulation of the battery. For the purposes of the present disclosure, the low degree of electrical conductivity exhibited by the thermally conductive filler is defined as approximately 9.9 x 10 5 S / m or less; alternatively, approximately 9.9 x 10 4 S / m or less. Alternatively, the electrical conductivity of the thermally conductive filler is low enough that the filler is classified as an electrical insulator.

[0043] The thermally conductive filler 75 includes a plurality of particles, the components of which include boron nitride, aluminum oxide, aluminum nitride, silicon nitride, silicon carbide, graphene, graphite, carbon nanotubes (single-walled or multi-walled) or a mixture of the above ingredients. The particles can have any feasible shape, including but not limited to spherical, flat (e.g., flakes), irregular or elongated (e.g., fibers). The particles can also be described as being in any feasible crystal form that provides thermal conductivity. Alternatively, when boron nitride is used as a thermally conductive filler, boron nitride provides a desired degree of thermal conductivity and electrical insulation for use in many applications. When boron nitride (BN) particles are used as thermally conductive fillers, boron nitride (BN) particles can include boron nitride in hexagonal crystal form (H-BN) or boron nitride in cubic crystal form (C-BN); alternatively, the thermally conductive filler is H-BN.

[0044] Still reference Figure 6 , the polymer matrix 80 includes an elastomer, a thermoplastic material, or a thermoplastic elastomer (TPE) having a Shore A hardness in the range of about 40 to 100, or a Shore D hardness in the range of 20 to about 75. Alternatively, the polymer matrix is ​​a thermoplastic elastomer (TPE) having a Shore A hardness in the range of about 50 to about 90, or a Shore D hardness in the range of about 45 to about 75; alternatively, a Shore A hardness in the range of about 70 to about 80. It can be used according to ASTM D22440 00, ISO 7619 and ISO 868; DIN53505; and / or JIS K 6301 (Durometer) test to measure Shore A hardness and / or Shore D hardness, JIS K 6301 has been superseded by JIS K 6253. Alternatively, the polymer matrix is ​​a thermoplastic material having a Shore D hardness in the range of about 60 to 75.

[0045] The TPE used as the polymer matrix 80 may include, but is not limited to, a styrene block copolymer (TPE-S), a polyolefin blend (TPE-O), a thermoplastic polyurethane (TPE-U), a thermoplastic copolyester (TPE-E), a thermoplastic polyamide (TPE-A), or a mixture of the above materials. Alternatively, the thermoplastic material used as the polymer matrix 80 is a high-density polyethylene (HDPE). The polymer matrix is ​​selected based on a combination of properties, including but not limited to hardness, cost, environmental impact, and a processing method that can be used to form a hollow structure of the cooling plate. The type of polymer matrix selected for a given application will affect the wall thickness t of the cooling plate to achieve the necessary compliance to provide the required or desired contact with the battery. According to one aspect of the present disclosure, the components of the composite material 70 include a plurality of boron nitride particles dispersed in a thermoplastic elastomer (TPE), the thermoplastic elastomer (TPE) having a Shore A hardness in the range of about 70 to about 80.

[0046] The thermally conductive filler 75 may be dispersed in the polymer matrix 80 using any mixing technique known to disperse solid particles into a liquid polymer. After mixing, the thermally conductive filler 75 comprises between about 5 wt.% and about 30 wt.% of the total weight of the composite material 70. Alternatively, the thermally conductive filler 75 comprises between about 5 wt.% and about 25 wt.% of the total weight of the composite material 70; alternatively, between about 10 wt.% and about 20 wt.% of the total weight of the composite material 70.

[0047] According to another aspect of the present disclosure, a battery pack with thermal management is provided. Figures 1 to 6 A battery pack generally includes at least one battery and a cooling plate configured as previously described and as otherwise defined herein. The cooling plate can be used to provide thermal management for at least one battery in an electric vehicle (EV) or a hybrid electric vehicle (HEV).

[0048] Reference now Figure 7 According to another aspect of the present disclosure, a process 100 for forming a battery pack as previously described and as otherwise defined herein is provided. The process 100 generally comprises the following steps: 105-providing a composite material; 110-performing a molding process on the composite material to form a hollow structure; 115-providing at least one battery; 120-assembling at least one battery with the hollow structure so that the battery is in thermal contact with the top section of the hollow structure; and 125-allowing a fluid to flow through one or more channels located within the hollow structure. The molding process 110 is generally selected from one of the group consisting of: blow molding, injection molding, compression molding, rotational molding; or a combination of the above processes.

[0049] When it is desired to form the top and bottom sections of the cooling plate separately, the process 100 may optionally include a joining step 130. The joining step 130 may include joining the top and bottom sections 35 together to form a "leak-free" hollow structure by using one or more of ultrasonic welding, spin welding, vibration welding, hot plate welding, infrared welding, laser welding, and overmolding techniques.

[0050] When a structural element configured to support the weight of the battery is incorporated into at least one of the channels in the cooling plate, the process may optionally include an additional forming step 135 for creating the structural element. The additional forming step 135 may include, but is not limited to, using a "ship in a bottle" technique in a blow molding process.

[0051] Finally, when the top section, the bottom section, or both the top section and the bottom section include one or more features, the process may optionally include an additional forming step 140 for creating one or more such features that protrude into one or more channels of the cooling plate to increase stiffness and / or promote fluid mixing by directing fluid flow. This additional forming step 140 is typically incorporated into the molding process 110 by including an additional step in creating a mold for the molding process, such as by using 3-D printing or positioning an insert in the mold.

[0052] Based on this disclosure, those skilled in the art will appreciate that multiple changes can be made to the specific embodiments disclosed herein and still achieve the same or similar results without departing from or exceeding the spirit or scope of this disclosure. Figures 1 to 7 The cooling plate and process for making the cooling plate depicted in the drawings show that the top section of the cooling plate is in contact with the bottom of the battery or battery module in the battery pack, but those skilled in the art will understand that the cooling plate can be reversed so that the top section of the cooling plate is in contact with the top surface of the battery or battery module without exceeding the scope of the present disclosure. Similarly, when a particular application requires or desires, the cooling plate can be configured so that the top section of the cooling plate is in thermal contact with one or more sides of the battery or battery module within the battery pack. Those skilled in the art will also understand that any characteristics reported herein represent characteristics that are conventionally measured and can be obtained by multiple different methods. The method described herein represents one such method and other methods may be used without exceeding the scope of the present disclosure.

[0053] The above description of various forms of the present invention is presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed. In light of the above teachings, multiple modifications or variations are possible. The forms discussed are selected and described to provide the best illustration of the principles of the present invention and its practical application, so that a person of ordinary skill in the art can utilize the present invention in various forms and make various modifications to adapt to the specific intended use. Therefore, the present invention is not limited to the above preferred exemplary embodiments in practice. On the contrary, multiple variations can be envisioned, which even utilize the described solutions in fundamentally different embodiments. All these modifications and variations are within the scope of the present invention as determined by the appended claims when interpreted according to the scope to which they are fairly, legally and equitably entitled.

Claims

1. A cooling plate for battery thermal management, the cooling plate comprising a composite material, the cooling plate being formed in the shape of a hollow structure, the components of the composite material comprising a thermally conductive filler, the thermally conductive filler being dispersed in a polymer matrix; in, The hollow structure has an outer wall, the thickness of the outer wall is in the range of about 0.3 mm (millimeter) to about 2.5 mm, and the hollow structure includes: a top section in thermal contact with at least one battery; a bottom section; said bottom section being integrally formed with said top section; and one or more channels, the one or more channels being located between the top section and the bottom section, The one or more channels are configured to allow a fluid to flow through the one or more channels to provide thermal management of the battery.

2. The cooling plate according to claim 1, wherein The thermal conductive filler comprises a plurality of particles, and components of the plurality of particles are selected from the group consisting of boron nitride, aluminum oxide, aluminum nitride, silicon nitride, silicon carbide, graphene, carbon nanotubes or a mixture of the above materials.

3. The cooling plate according to claim 1 or 2, wherein: The polymer matrix is ​​an elastomer, a thermoplastic material or a thermoplastic elastomer (TPE), wherein the Shore A hardness of the elastomer, the thermoplastic material or the thermoplastic elastomer (TPE) is in the range of about 40 to 100, or the Shore D hardness of the elastomer, the thermoplastic material or the thermoplastic elastomer (TPE) is in the range of 20 to about 75.

4. The cooling plate according to any one of claims 1 to 3, wherein: The components of the composite material include a plurality of boron nitride particles dispersed in a thermoplastic elastomer (TPE) having a Shore A hardness ranging from about 70 to about 80.

5. The cooling plate according to any one of claims 1 to 4, wherein: The thermally conductive filler has a low degree of electrical conductivity.

6. The cooling plate according to any one of claims 1 to 5, wherein: The one or more channels include structural elements configured to support the weight of the battery.

7. The cooling plate according to any one of claims 1 to 6, wherein: at least one of the bottom section and the top section includes one or more features configured to increase stiffness and promote fluid mixing by directing the fluid flow; Wherein at least one of the features protrudes into the one or more channels from the top section, the bottom section, or both the top section and the bottom section.

8. The cooling plate according to any one of claims 1 to 7, wherein: The top section is flat to maintain at least 50% surface contact with the battery.

9. The cooling plate according to any one of claims 1 to 8, wherein: The top section includes one or more bumper stops configured to assist in placement and retention of a battery.

10. The cooling plate according to any one of claims 1 to 9, wherein: The wall thickness is in the range of about 1.0 mm to about 2.0 mm.

11. The cooling plate according to claim 6, wherein: The composition of the structural element is different from the composition of the cooling plate.

12. The cooling plate according to any one of claims 1 to 11, wherein: The hollow structure changes in volume by less than about 15% when allowing the fluid to flow through the one or more channels.

13. The cooling plate according to any one of claims 1 to 12, wherein: The hollow structure is formed as a single component.

14. The cooling plate according to any one of claims 1 to 13, wherein: The thermally conductive filler accounts for between about 5 wt. % and about 25 wt. % of the total weight of the composite material.

15. A battery pack with thermal management, wherein: The battery pack comprises: at least one battery; and A cooling plate according to any one of claims 1 to 14; wherein the cooling plate comprises a composite material, the cooling plate is formed in the shape of a hollow structure, the components of the composite material include a thermally conductive filler, and the thermally conductive filler is dispersed in a polymer matrix; The hollow structure has an outer wall, the thickness of the outer wall is in the range of about 0.3 mm (millimeter) to about 2.5 mm, and the hollow structure includes: a top section in thermal contact with the at least one battery; a bottom section; said bottom section being integrally formed with said top section; and One or more channels are located between the top section and the bottom section, the one or more channels being configured to allow a fluid to flow through the one or more channels to provide thermal management of the battery pack.

16. The battery pack according to claim 15, wherein: The thermally conductive filler comprises a plurality of particles, and components of the plurality of particles are selected from the group consisting of: boron nitride, aluminum oxide, silicon nitride, graphene, carbon nanotubes, or a mixture of the above materials; wherein the polymer matrix is ​​an elastomer, a thermoplastic material or a thermoplastic elastomer (TPE), the elastomer, the thermoplastic material or the thermoplastic elastomer (TPE) having a Shore A hardness in the range of about 40 to 100, or the elastomer, the thermoplastic material or the thermoplastic elastomer (TPE) having a Shore D hardness in the range of 20 to about 75; The thermal conductive filler accounts for between about 5 wt. % and about 25 wt. % of the total weight of the composite material.

17. Use of a cooling plate according to any one of claims 1 to 14 for providing thermal management for at least one battery in an electric vehicle (EV) or a hybrid electric vehicle (HEV).

18. A process for forming a battery pack configured for thermal management according to claim 15 or 16, wherein: The process comprises: Providing composite materials; performing a molding process on the composite material to form an inner hollow structure; providing at least one battery; assembling the at least one battery with the hollow structure such that the battery is in thermal contact with a top section of the hollow structure; and Fluid is allowed to flow through one or more channels located within the hollow structure.

19. The process of claim 18, wherein: The molding process is selected from one of the group consisting of blow molding, injection molding, compression molding, rotational molding, or a combination of the above processes.

20. The process of claim 18 or 19, wherein: The process also includes: forming one or more structural elements within at least one channel, the one or more structural elements configured to support the weight of the battery, the one or more structural elements having a composition different from that of the cooling plate; and / or One or more features are formed that protrude from the top segment, the bottom segment, or both into the one or more channels, the features configured to increase stiffness and promote fluid mixing by directing the fluid flow.

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