Immersed cooled battery array housing

Abstract

The present disclosure provides a "submerged cooled battery array enclosure". An assembly includes a first housing member and a second housing member that cooperates with the first housing member to provide a closed interior cavity. At least one cell stack includes one or more battery cells positioned within the closed interior cavity. A first plurality of guide features is formed on at least one of the first housing part and the second housing part, and a second plurality of guide features is formed on the at least one of the first housing part and the second housing part.

Description

Technical Field

[0001] The present disclosure generally relates to a battery array housing structure assembly suitable for immersion cooling of a battery array of a traction battery pack, and more particularly to a housing structure assembly including multiple sets of flow directing features. Background Art

[0002] Electrified vehicles are a type of vehicle designed to reduce automotive fuel consumption and emissions. Generally, they differ from conventional motor vehicles powered by internal combustion engines in that they are selectively driven by one or more battery-powered electric motors. A high-voltage traction battery pack typically supplies power to the electric motors and other electrical loads in the electrified vehicle. A traction battery pack may include one or more interconnected groups of battery cells. A thermal management system may be used to facilitate control of the thermal characteristics of the traction battery pack. Summary of the Invention

[0003] An assembly according to an exemplary aspect of the present disclosure includes, inter alia: a first housing member; a second housing member cooperating with the first housing member to provide a closed internal cavity; at least one cell stack comprising one or more battery cells positioned within the closed internal cavity; a first plurality of guide features formed on at least one of the first housing member and the second housing member; and a second plurality of guide features formed on at least one of the first housing member and the second housing member.

[0004] In a further non-limiting embodiment of the foregoing assembly, the first housing component comprises a battery housing top cover, and wherein the second housing component comprises a battery housing bottom cover.

[0005] In a further non-limiting embodiment of any of the foregoing assemblies, the first plurality of guide features comprises mechanical support for the one or more battery cells.

[0006] In a further non-limiting embodiment of any one of the foregoing assemblies, at least one of the first housing component and the second housing component includes an inner surface facing the enclosed internal cavity, and wherein the first plurality of guide features includes discrete elongated bodies extending outwardly from the inner surface to provide a fluid flow channel.

[0007] In a further non-limiting embodiment of any of the foregoing assemblies, the second plurality of guide features extends outwardly from the inner surface and comprises a plurality of discrete protrusions or dimples spaced apart from one another within the fluid flow passage.

[0008] In another non-limiting embodiment of any of the foregoing assemblies, the discrete elongated bodies are defined by a first height relative to the inner surface, and the plurality of discrete protrusions or recesses are defined by a second height relative to the inner surface, wherein the second height is less than the first height.

[0009] In a further non-limiting embodiment of any one of the foregoing assemblies, at least one of the first housing member and the second housing member includes an inner surface facing the enclosed internal cavity, and wherein the first plurality of guide features include mechanical supports for the one or more battery cells, and wherein the first plurality of guide features include discrete elongated bodies extending outwardly from the inner surface to provide a fluid flow channel.

[0010] In a further non-limiting embodiment of any of the foregoing assemblies, the length includes a thermal interface material between the first plurality of guide features and the one or more battery cells.

[0011] In a further non-limiting embodiment of any of the foregoing assemblies, the discrete elongated bodies each extend away from the inner surface to a distal surface, and wherein the thermal interface material covers the distal surface.

[0012] In a further non-limiting embodiment of any one of the foregoing assemblies, at least one of the first housing component and the second housing component includes an inner surface facing the enclosed interior cavity, wherein the first plurality of guide features are defined by a first height relative to the inner surface and the second plurality of guide features are defined by a second height relative to the inner surface, wherein the second height is less than the first height.

[0013] In a further non-limiting embodiment of any of the foregoing assemblies, the other of the first housing component and the second housing component includes a set of the first plurality of guide features and a set of the second plurality of guide features.

[0014] In a further non-limiting embodiment of any one of the foregoing assemblies, the first plurality of guide features comprises a plurality of primary protrusions extending away from the housing surface, and the second plurality of guide features comprises a plurality of auxiliary protrusions extending away from the housing surface and having a different height relative to the housing surface than the plurality of primary protrusions.

[0015] In a further non-limiting embodiment of any one of the foregoing assemblies, each main protrusion comprises an elongated body that provides support for the one or more battery cells, and wherein adjacent main protrusions are spaced apart from one another to define a fluid flow channel, and wherein the plurality of auxiliary protrusions comprise discrete recesses that are spaced apart from one another within the fluid flow channel.

[0016] A method according to an exemplary aspect of the present disclosure includes, inter alia, providing a first housing component and a second housing component, the second housing component cooperating with the first housing component to provide a closed internal cavity; positioning at least one battery cell stack comprising one or more battery cells within the closed internal cavity; forming a first plurality of guide features on at least one of the first housing component and the second housing component; and forming a second plurality of guide features on the at least one of the first housing component and the second housing component.

[0017] In a further non-limiting embodiment of the foregoing method, at least one of the first shell component and the second shell component includes an inner surface facing the enclosed internal cavity, and the method includes: defining the first plurality of guide features using a first height relative to the inner surface; and defining the second plurality of guide features using a second height relative to the inner surface, wherein the second height is less than the first height.

[0018] In a further non-limiting embodiment of any of the foregoing methods, at least one of the first and second case components includes an interior surface facing the enclosed interior cavity, and the method includes forming the first plurality of guide features as mechanical supports for the one or more battery cells.

[0019] In a further non-limiting embodiment of any of the foregoing methods, the method includes forming the first plurality of guide features as discrete elongated bodies extending outwardly from the inner surface to provide fluid flow channels.

[0020] In a further non-limiting embodiment of any of the foregoing methods, the discrete elongated bodies each extend away from the inner surface to a distal surface, and the method includes covering the distal surface with a thermal interface material and forming an isolation structure between the first plurality of guide features and the one or more battery cells.

[0021] In a further non-limiting embodiment of any of the foregoing methods, the other of the first housing component and the second housing component includes a set of the first plurality of guide features and a set of the second plurality of guide features.

[0022] In a further non-limiting embodiment of any one of the foregoing methods, the first housing member and the second housing member include an inner surface facing the enclosed internal cavity, and the method includes: forming the first plurality of guide features as a plurality of main protrusions extending away from the inner surface, wherein each main protrusion includes a slender body that provides support to the one or more battery cells, and wherein adjacent main protrusions are spaced apart from each other to define a fluid flow channel; and forming the second plurality of guide features as a plurality of auxiliary protrusions extending away from the inner surface and having a different height than the plurality of main protrusions, wherein the plurality of auxiliary protrusions include discrete pits that are spaced apart from each other within the fluid flow channel.

[0023] The embodiments, examples and alternatives of the preceding paragraphs, claims or following description and drawings, including any of their various aspects or corresponding individual features, may be taken independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] According to the detailed description, the various features and advantages of the disclosed examples will become apparent to those skilled in the art. The drawings accompanying the detailed description can be briefly described as follows:

[0025] Figure 1 An electrified vehicle is schematically shown.

[0026] Figure 2 Shown Figure 1 Traction battery packs for electrified vehicles.

[0027] Figure 3 Shown Figure 2 Exploded view of the traction battery pack.

[0028] Figure 4A is an enlarged view of a portion of the inner surface of the bottom cover of the traction battery pack.

[0029] Figure 4B It is along the Figure 4A A cross-sectional view taken along line 4B-4B is shown.

[0030] Figure 5A This is a bottom view of the top cover of the traction battery pack.

[0031] Figure 5B is an enlarged view of a portion of the inner surface of the top cover of the traction battery pack. DETAILED DESCRIPTION

[0032] This disclosure details a battery array housing structure assembly suitable for immersion cooling of a battery array of a traction battery pack. The housing structure assembly includes multiple flow-directing features to facilitate thermal management of the traction battery pack. These and other features are discussed in greater detail in the following sections of this detailed description.

[0033] Figure 1 An electrified vehicle 10 is schematically shown. The electrified vehicle 10 may include any type of electrified powertrain. In an embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and may be extended to other electrified vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, and the like. Thus, although not specifically shown in the exemplary embodiment, the powertrain of the electrified vehicle 10 may be equipped with an internal combustion engine, which may be employed alone or in combination with other power sources to propel the electrified vehicle 10.

[0034] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 may alternatively be a sport utility vehicle (SUV), a van, a pickup truck, or any other vehicle configuration. Although specific component relationships are shown in the figures of the present disclosure, the illustrations are not intended to limit the present disclosure. The placement and orientation of the various components of the electrified vehicle 10 are shown schematically and may vary within the scope of the present disclosure. In addition, the various figures accompanying the present disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to emphasize certain details of a particular component or system.

[0035] In an embodiment, the electrified vehicle 10 is a pure electric vehicle that is propelled solely by electricity, such as by one or more electric machines 12, without any assistance from an internal combustion engine. The electric machines 12 can operate as electric motors, generators, or both. The electric machines 12 receive electrical power and can convert the power into torque for driving one or more wheels 14 of the electrified vehicle 10.

[0036] A voltage bus 16 can electrically couple the electric machine 12 to a traction battery pack 18. The traction battery pack 18 is an exemplary electric vehicle battery. The traction battery pack 18 can be a high-voltage traction battery pack assembly that includes a plurality of battery cell groups capable of outputting electrical power to power the electric machine 12 and / or other electrical loads of the electric vehicle 10. Other types of energy storage devices and / or output devices can alternatively or additionally be used to power the electric vehicle 10.

[0037] The traction battery pack 18 may be secured to an underbody 20 of the electrified vehicle 10. However, the traction battery pack 18 may be located elsewhere on the electrified vehicle 10 within the scope of the present disclosure.

[0038] Figure 2 and Figure 3 Additional details associated with the traction battery pack 18 of the electrified vehicle 10 are shown. The traction battery pack 18 can include one or more cell stacks 22 housed within an interior region 30 of a battery housing enclosure assembly 24. The enclosure assembly 24 includes at least a first enclosure member 26 and a second enclosure member 28 that cooperate with each other to define an enclosed interior cavity 30 of the traction battery pack 18. In one example, the first enclosure member 26 can include a housing top cover 26, and the second enclosure member 28 can include a housing tray or bottom cover 28. The housing cover 26 can be secured (e.g., bolted, welded, adhered, etc.) to the housing tray or bottom cover 28 to provide an interior region 30 for housing the cell stacks 22 and other battery internal components of the traction battery pack 18 (e.g., bus bars, control modules, other electronics, etc.). The size, shape, and configuration of the enclosure assembly 24 can vary within the scope of the present disclosure.

[0039] Each cell stack 22 may include a plurality of individual battery cells 32 within an enclosed interior cavity 30 . The battery cells 32 store and supply electricity for powering various components to support electric propulsion of the electrified vehicle 10 .

[0040] In one embodiment, the battery cells 32 are lithium-ion pouch cells. However, within the scope of the present disclosure, battery cells having other geometries (cylindrical, prismatic, etc.) and / or chemistries (nickel-metal hydride, lead acid, etc.) may alternatively be utilized.

[0041] Although a specific number of cell stacks 22 and battery cells 32 are shown in the various figures of the present disclosure, the traction battery pack 18 may include any number of cell stacks 22, with each cell stack 22 having any number of individual battery cells 32. The battery cells 32 of each cell stack 22 may be stacked side by side relative to each other along the cell stack axis. The battery cells 32 may be arranged so that the face of one battery cell is in direct contact with one of the faces of an adjacent battery cell 32 of the cell stack 22. The battery cells 32 may be held in compression relative to each other within the cell stack 22 to provide a face-to-face cell arrangement. For example, support and / or compression may be applied by a support structure 34 of the cell stack 22. However, other configurations are contemplated within the scope of the present disclosure. The support structure 34 may include any combination of plates, walls, beams, beams, bindings, and the like.

[0042] In one example, the traction battery pack 18 utilizes immersion cooling, which has the benefits of promoting cooling efficiency and mitigating heat spread. To leverage these benefits, the contact area between the coolant and the battery cells 32, as well as between the coolant and the thermally conductive housing components 26 and 28, should be maximized. However, the battery cells 32 in the array need to be mechanically supported due to their weight. The support structure and the coolant flow domain occupy the same space. In addition, due to packaging space constraints, the cross-sectional area of the coolant flow channel is limited, which may affect cooling efficiency. The present disclosure provides a configuration that simultaneously supports the battery cells 32, provides space for the coolant to cool the battery cells 32, and improves cooling efficiency within the limited space.

[0043] In one example, first and second plurality of guide features 40, 42 are formed on at least one of first and second case components 26, 28. As described above, in one example, first case component comprises battery housing top cover 26 and second case component comprises battery housing bottom cover 28.

[0044] The bottom cover 28 includes an inner surface 44 ( Figures 4A to 4B ), and the top cover 26 includes an inner surface 46 ( Figures 5A to 5B In one example, each of the top cover 26 and the bottom cover 28 includes a first plurality of guide features 40 and a second plurality of guide features 42. In one example, the first plurality of guide features 40 includes a set of primary guide and cooling features, and the second plurality of guide features includes a set of auxiliary guide and cooling features.

[0045] In one example, the first plurality of guide features 40 include mechanical supports for one or more battery cells 32. The mechanical supports extend from respective inner surfaces (44 and / or 46) of the covers (26 and / or 28) to contact the battery cells 32 and structurally support them.

[0046] like Figure 4A As shown, in one example, the first plurality of guide features 40 include protrusions, such as discrete elongated bodies 48, extending outwardly from the inner surface 44 of the bottom cover 28 to provide a plurality of fluid flow channels 50. The elongated bodies 48 are spaced apart from each other across the inner surface 44. The fluid flow channels 50 are formed in the gaps created between the elongated bodies 48.

[0047] In one example, a second plurality of guide features 42 extends outward from the inner surface 44 of the bottom cover 28 and includes protrusions, such as a plurality of discrete dimples 52, spaced apart from one another within the fluid flow channel 50. The dimples 52 help improve cooling efficiency by disrupting the coolant flow and increasing turbulence. The dimples 52 also improve cooling efficiency by increasing the contact area between the housing cavity 30 (e.g., a radiator) and the coolant circulating within the cavity 30. In certain circumstances, such as heat spread, the dimples 52 help cool down the exhaust gas temperature by increasing mixing between the coolant and the exhaust gas and increasing the contact area between the housing and the exhaust gas. Although the addition of the auxiliary dimples 52 slightly increases the coolant pressure drop across the housing, it does not affect coolant pump performance because the pressure drop in the housing is a small fraction of the total pressure drop of the coolant throughout the vehicle thermal system.

[0048] In one example, the elongated body 48 is defined by a first height H1 relative to the inner surface 44, and the plurality of discrete dimples 52 are defined by a second height H2 relative to the inner surface 44. In one example, the first height H1 and the second height H2 are different from each other. In one example, the second height H2 is less than the first height H1. Having the second height H2 less than the first height H1 promotes turbulence within the fluid flow channel 50.

[0049] In one example, the first plurality of guide features 40 and the second plurality of guide features 42 cooperate to provide two distinct layers of features that help guide the coolant and improve cooling efficiency. The number, shape, size, and pattern of the two distinct layers of features 40, 42 depend on the requirements for cell support, cooling efficiency, and mixing efficiency.

[0050] Figures 5A to 5B An example of a top cover 26 is shown that includes both a first plurality of guide features 40 and a second plurality of guide features 42. An elongated body 48 and a plurality of discrete dimples 52 extend away from the inner surface 46 of the top cover 26 in a manner similar to that described above with respect to the bottom cover 28.

[0051] For example, the covers 26, 28 may be made of a thermally conductive material such as, for example, metal. In one example, a thermal interface material layer 54 ( Figure 4B The use of the thermal interface material layer 54 helps to isolate the thermally conductive covers 26, 28 from the battery cells 32. Figure 4B In one example shown, the discrete elongated bodies 48 each extend away from the inner surface 44 to a distal surface 56. In one example, the thermal interface material layer 54 covers the distal surface 56. In one example, the thermal interface material layer 54 is associated only with the first plurality of guide features 40. In one example, only the distal surface 56 is covered by the thermal interface material layer 54.

[0052] The following are examples of interface materials: thermal paste; thermal adhesive; thermal gap filler; or other similar materials. The interface material should be thermally conductive to transfer heat, have a tacky texture to increase cell retention, and be thicker than a predetermined value to provide electrical insulation between the battery cell and the cover.

[0053] In one example, a method includes providing a first housing member and a second housing member, the second housing member cooperating with the first housing member to provide an enclosed internal cavity; positioning at least one battery cell stack comprising one or more battery cells within the enclosed internal cavity; forming a first plurality of guide features on at least one of the first housing member and the second housing member; and forming a second plurality of guide features on the at least one of the first housing member and the second housing member.

[0054] The method may further include any of the following steps, alone or in any combination. For example, the method may include: at least one of the first housing component and the second housing component includes an inner surface facing the enclosed interior cavity, and the method further includes: defining the first plurality of guide features using a first height relative to the inner surface; and defining the second plurality of guide features using a second height relative to the inner surface, wherein the second height is less than the first height.

[0055] For example, the method may include forming the first plurality of guide features as mechanical supports for the one or more battery cells.

[0056] For example, the method may include forming the first plurality of guide features as discrete elongated bodies extending outwardly from the inner surface to provide fluid flow channels.

[0057] For example, the method may include each of the discrete elongated bodies extending away from the inner surface to a distal surface, and the method further comprising covering the distal surface with a thermal interface material and forming an isolation structure between the first plurality of guide features and the one or more battery cells.

[0058] For example, the method can include the other of the first housing component and the second housing component including a set of the first plurality of guide features and a set of the second plurality of guide features.

[0059] For example, the method may include forming the first plurality of guide features into a plurality of main protrusions extending away from the inner surface, wherein each main protrusion comprises an elongated body that provides support to the one or more battery cells, and wherein adjacent main protrusions are spaced apart from one another to define a fluid flow channel; and forming the second plurality of guide features into a plurality of auxiliary protrusions extending away from the inner surface and having a different height than the plurality of main protrusions, wherein the plurality of auxiliary protrusions comprise discrete recesses that are spaced apart from one another within the fluid flow channel.

[0060] The present disclosure provides a battery array housing, such as a top cover and a bottom cover, having two layers of protrusions / pits of different heights. The main layer (e.g., the first layer) of protrusions is used to support the battery cells, and the space between the protrusions forms a coolant flow channel that allows the coolant to directly contact the edge of the battery cell. Between the main protrusions and the battery cells, an interface material layer can be added to isolate the battery cells from the conductive housing. Inside each coolant channel formed by the main protrusions, an auxiliary layer (e.g., the second layer) of pits is added. The pits are shorter than the main protrusions and do not contact the battery cells. The pits are used to disrupt the coolant flow and increase its turbulence, which helps to improve cooling efficiency. In addition, the auxiliary pits increase the contact area between the coolant and the housing. Since the housing is typically made of metal and acts as a heat sink, the larger contact area between the housing and the coolant helps to remove heat from the coolant more quickly, which further improves the cooling capacity of the coolant. In the event of heat transfer, hot exhaust gases are discharged from the battery cells. The auxiliary dimples can improve the mixing efficiency between the gas and the coolant and increase the contact area between the gas and the housing, which helps to cool the exhaust gas and reduce the heat transfer rate.

[0061] The addition of auxiliary dimples slightly increases the coolant pressure drop across the array. Computational fluid dynamics analysis shows that, in this example of the dimple pattern, the addition of auxiliary dimples increases the heat transfer coefficient between the battery cells and the coolant by approximately 7%. After adding the auxiliary dimples, the pressure drop across the housing increases by approximately 10%. Compared to conventional cold plate cooling, the resistance to coolant flow in the housing is much less than the resistance in the cold plate coolant channels, so the coolant pressure drop in the housing is lower than the pressure drop in the cold plate. Therefore, the pressure drop in the array is not a major factor in the coolant pressure drop in the entire vehicle thermal system. Therefore, the increase in pressure drop due to the auxiliary dimples does not significantly affect coolant pump performance.

[0062] The foregoing description is illustrative rather than restrictive in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art, and such variations and modifications do not necessarily depart from the essence of the present disclosure. Therefore, the scope of protection afforded to the present disclosure should be determined solely by studying the appended claims.

[0063] According to the present invention, an assembly is provided, comprising: a first housing member; a second housing member, the second housing member cooperating with the first housing member to provide a closed internal cavity; at least one cell stack, the at least one cell stack comprising one or more battery cells positioned within the closed internal cavity; a first plurality of guide features formed on at least one of the first housing member and the second housing member; and a second plurality of guide features formed on the at least one of the first housing member and the second housing member.

[0064] According to an embodiment, the first housing component comprises a battery housing top cover, and wherein the second housing component comprises a battery housing bottom cover.

[0065] According to an embodiment, the first plurality of guide features comprises mechanical support for the one or more battery cells.

[0066] According to an embodiment, at least one of the first and second housing components comprises an inner surface facing the enclosed interior cavity, and wherein the first plurality of guide features comprises discrete elongated bodies extending outwardly from the inner surface to provide a fluid flow channel.

[0067] According to an embodiment, the second plurality of guide features extends outwardly from the inner surface and comprises a plurality of discrete protrusions or depressions spaced apart from one another within the fluid flow channel.

[0068] According to an embodiment, the discrete elongated bodies are defined by a first height relative to the inner surface, and the plurality of discrete protrusions or recesses are defined by a second height relative to the inner surface, wherein the second height is less than the first height.

[0069] According to an embodiment, at least one of the first and second housing components comprises an inner surface facing the enclosed internal cavity, and wherein the first plurality of guide features comprises a mechanical support for the one or more battery cells, and wherein the first plurality of guide features comprises discrete elongated bodies extending outwardly from the inner surface to provide a fluid flow channel.

[0070] According to an embodiment, the invention also features a thermal interface material between the first plurality of guide features and the one or more battery cells.

[0071] According to an embodiment, the discrete elongated bodies each extend away from the inner surface to a distal surface, and wherein the thermal interface material covers the distal surface.

[0072] According to an embodiment, at least one of the first housing component and the second housing component includes an inner surface facing the closed internal cavity, wherein the first plurality of guide features are defined by a first height relative to the inner surface and the second plurality of guide features are defined by a second height relative to the inner surface, wherein the second height is less than the first height.

[0073] According to an embodiment, the other of the first housing component and the second housing component comprises a set of the first plurality of guide features and a set of the second plurality of guide features.

[0074] According to an embodiment, the first plurality of guide features comprises a plurality of main protrusions extending away from the housing surface, and the second plurality of guide features comprises a plurality of auxiliary protrusions extending away from the housing surface and having a different height relative to the housing surface than the plurality of main protrusions.

[0075] According to an embodiment, each main protrusion comprises an elongated body that provides support for the one or more battery cells, and wherein adjacent main protrusions are spaced apart from each other to define a fluid flow channel, and wherein the plurality of auxiliary protrusions comprise discrete recesses that are spaced apart from each other within the fluid flow channel.

[0076] According to the present invention, a method includes: providing a first housing component and a second housing component, wherein the second housing component cooperates with the first housing component to provide an enclosed internal cavity; positioning at least one battery cell stack including one or more battery cells within the enclosed internal cavity; forming a first plurality of guide features on at least one of the first housing component and the second housing component; and forming a second plurality of guide features on the at least one of the first housing component and the second housing component.

[0077] In one aspect of the present invention, at least one of the first shell component and the second shell component includes an inner surface facing the enclosed internal cavity, and the method includes: defining the first plurality of guide features using a first height relative to the inner surface; and defining the second plurality of guide features using a second height relative to the inner surface, wherein the second height is less than the first height.

[0078] In one aspect of the invention, the at least one of the first and second housing components includes an interior surface facing the enclosed interior cavity, and the method includes forming the first plurality of guide features as mechanical supports for the one or more battery cells.

[0079] In one aspect of the invention, the method includes forming the first plurality of guide features as discrete elongated bodies extending outwardly from the interior surface to provide fluid flow channels.

[0080] In one aspect of the invention, the discrete elongated bodies each extend away from the inner surface to a distal surface, and the method includes covering the distal surface with a thermal interface material and forming an isolation structure between the first plurality of guide features and the one or more battery cells.

[0081] In one aspect of the present invention, the other of the first housing component and the second housing component includes a set of the first plurality of guide features and a set of the second plurality of guide features.

[0082] In one aspect of the invention, the first housing member and the second housing member include an inner surface facing the enclosed internal cavity, and the method includes: forming the first plurality of guide features as a plurality of main protrusions, the plurality of main protrusions extending away from the inner surface, wherein each main protrusion includes a slender body that provides support to the one or more battery cells, and wherein adjacent main protrusions are spaced apart from each other to define a fluid flow channel; and forming the second plurality of guide features as a plurality of auxiliary protrusions, the plurality of auxiliary protrusions extending away from the inner surface and having a different height than the plurality of main protrusions, wherein the plurality of auxiliary protrusions include discrete pits that are spaced apart from each other within the fluid flow channel.

Claims

1. An assembly comprising: a first housing component; a second housing component that cooperates with the first housing component to provide a closed interior cavity; at least one battery cell stack comprising one or more battery cells positioned within the enclosed interior cavity; a first plurality of guide features formed on at least one of the first housing component and the second housing component; as well as A second plurality of guide features is formed on the at least one of the first housing component and the second housing component.

2. The assembly of claim 1 , wherein the first housing component comprises a battery housing top cover, and wherein the second housing component comprises a battery housing bottom cover. 3 . The assembly of claim 1 , wherein the first plurality of guide features comprises mechanical support for the one or more battery cells.

4. The assembly of claim 1 , wherein said at least one of said first and second housing components includes an inner surface facing said enclosed interior cavity, and wherein said first plurality of guide features includes discrete elongated bodies extending outwardly from said inner surface to provide a fluid flow channel. 5 . The assembly of claim 4 , wherein the second plurality of guide features extend outwardly from the inner surface and comprise a plurality of discrete protrusions or depressions spaced apart from one another within the fluid flow passage.

6. The assembly of claim 5, wherein the discrete elongated body is defined by a first height relative to the inner surface, and the plurality of discrete protrusions or recesses are defined by a second height relative to the inner surface, wherein the second height is less than the first height.

7. The assembly of claim 1 , wherein said at least one of said first and second housing components comprises an interior surface facing said enclosed interior cavity, and wherein said first plurality of guide features comprises mechanical supports for said one or more battery cells, and wherein said first plurality of guide features comprises discrete elongated bodies extending outwardly from said interior surface to provide fluid flow channels.

8. The assembly of claim 7 , comprising a thermal interface material between the first plurality of guide features and the one or more battery cells, and optionally, wherein the discrete elongated bodies each extend away from the inner surface to a distal surface, and wherein the thermal interface material covers the distal surface.

9. The assembly of claim 1 , wherein said at least one of said first and second housing components includes an inner surface facing said enclosed interior cavity, wherein said first plurality of guide features are defined by a first height relative to said inner surface, and wherein said second plurality of guide features are defined by a second height relative to said inner surface, wherein said second height is less than said first height.

10. The assembly of claim 1 , wherein the other of the first and second housing components comprises a set of the first plurality of guide features and a set of the second plurality of guide features, and wherein the first plurality of guide features comprises a plurality of primary protrusions extending away from the housing surface, and the second plurality of guide features comprises a plurality of auxiliary protrusions extending away from the housing surface and having a different height relative to the housing surface than the plurality of primary protrusions, and optionally, wherein each primary protrusion comprises an elongated body that provides support for the one or more battery cells, and wherein adjacent primary protrusions are spaced apart from one another to define a fluid flow channel, and wherein the plurality of auxiliary protrusions comprise discrete recesses spaced apart from one another within the fluid flow channel.

11. A method comprising: providing a first housing component and a second housing component, the second housing component cooperating with the first housing component to provide an enclosed interior cavity; positioning at least one cell stack comprising one or more battery cells within the enclosed interior cavity; forming a first plurality of guide features on at least one of the first housing component and the second housing component; as well as A second plurality of guide features is formed on the at least one of the first housing component and the second housing component.

12. The method of claim 11 , wherein the at least one of the first housing component and the second housing component includes an inner surface facing the enclosed interior cavity, and the method comprises: defining the first plurality of guide features with a first height relative to the interior surface; as well as The second plurality of guide features is defined by a second height relative to the inner surface, wherein the second height is less than the first height.

13. The method of claim 11 , wherein the at least one of the first and second housing components includes an interior surface facing the enclosed interior cavity, and the method includes forming the first plurality of guide features as mechanical supports for the one or more battery cells.

14. The method of claim 13 , comprising forming the first plurality of guide features into discrete elongated bodies extending outwardly from the inner surface to provide fluid flow channels, and optionally wherein the discrete elongated bodies each extend away from the inner surface to a distal surface, and the method comprising covering the distal surface with a thermal interface material and forming an isolation structure between the first plurality of guide features and the one or more battery cells.

15. The method of claim 14, wherein the other of the first and second housing components comprises a set of the first and second plurality of guide features, and wherein the first and second housing components comprise interior surfaces facing the enclosed interior cavity, and the method comprises: forming the first plurality of guide features as a plurality of main protrusions extending away from the inner surface, wherein each main protrusion includes an elongated body that provides support to the one or more battery cells, and wherein adjacent main protrusions are spaced apart from one another to define a fluid flow channel; as well as The second plurality of guide features is formed as a plurality of auxiliary protrusions extending away from the inner surface and having a different height than the plurality of primary protrusions, wherein the plurality of auxiliary protrusions include discrete dimples spaced apart from one another within the fluid flow channel.

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