Conformal fluid-cooled heat exchanger for batteries

Abstract

Method for assembling a battery unit (100, 300, 400) which comprises: Providing a substantially rigid heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) which provides an internal fluid passage (118, 126, 218, 226, 308, 408) for a heat exchanger fluid and has at least one flexible region (230, 324, 326, 352, 354, 370, 380, 424, 426); and Positioning at least a part of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) between two battery modules (102(1) - 102(6), 304(1)-304(2)), each of the battery modules (102(1) - 102(6), 304(1)-304(2)) comprising at least one battery cell (106) contained in a rigid container (104), and wherein the positioning of at least a part of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) involves at least a temporary deformation or displacement of the at least one compliant region (230, 324, 326, 352, 354, 370, 380, 424, 426) of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)).

Description

Cross-reference to related registration

[0001] This application claims the benefit and priority of provisional US patent application No. 61 / 389 301, which was filed on October 4, 2010, under the title CONFORMAL FLUID-COOLED HEAT EXCHANGER FOR BATTERY CELL STACK.

[0002] The content of the aforementioned patent application is hereby expressly incorporated by reference to its detailed description. background

[0003] This disclosure relates to heat exchangers used for dissipating heat in rechargeable batteries and other electricity-generating cells.

[0004] Rechargeable batteries, such as those consisting of many lithium-ion cells, can be used in many applications, including electric vehicles (EVs) and electric hybrid vehicles (HEVs), among others. These batteries can generate large amounts of heat that must be dissipated.

[0005] Document JP 2000-048867 A relates to a battery pack consisting of several batteries arranged one above the other and a spacer between the batteries. The spacer consists of a corrugated, plate-shaped spring and is arranged such that a groove extends in the vertical direction. The groove is designed as a cooling channel for conveying a cooling medium. The batteries deform when the internal pressure increases during the charging process, but the pressure force caused by the deformation of the batteries is absorbed by the elastic deformation of the spacer. Document WO 2003 / 071616 A2 discloses a device for cooling electrochemical cells of an energy storage device, in which the electrochemical cells are arranged in a spaced-apart relationship. A cooling bladder ensures temperature control of the energy storage device.Publication US 2007 / 0285051 A1 deals with barriers with front surfaces designed to contact battery units and curved to bend elastically. Summary

[0006] The present invention is specified in the independent claims. Individual embodiments are described in the dependent claims. According to one embodiment, a method for assembling a battery unit is provided, comprising: providing a substantially rigid heat exchanger that defines an internal fluid passage for a heat exchanger fluid and has at least one compliant region; and positioning at least a part of the heat exchanger between two battery modules, each of which has at least one battery cell contained within a rigid container, and wherein the positioning of at least a part of the heat exchanger involves at least temporary deformation or displacement of the at least one compliant region of the heat exchanger.

[0007] According to one embodiment, a battery unit is provided with a heat exchanger and two battery modules, each of which has at least one battery cell housed within a rigid container, and wherein the heat exchanger defines an internal fluid passage for a heat exchanger fluid and has at least one compliant area designed to be compressible to facilitate thermal contact between the heat exchanger and the two battery modules. At least part of the heat exchanger is positioned between the two battery modules.

[0008] According to one embodiment, a heat exchanger for exchanging thermal energy with battery modules is provided, which has: several heat exchanger plates, each defining an internal fluid passage for a heat exchanger fluid and having compliant protrusions formed integrally with them, which heat exchanger plates are arranged in a stack with adjacent heat exchanger plates, which have a mutual distance and are connected to each other by the compliant protrusions in order to allow compression of the adjacent heat exchanger plates following the insertion of battery modules between the heat exchanger plates.According to one embodiment, a heat exchanger for exchanging thermal energy with battery modules is provided, comprising several heat exchanger plates, each defining an internal fluid flow passage for a heat exchanger fluid, and arranged in a stack in which adjacent heat exchanger plates are spaced apart, wherein the adjacent heat exchanger plates are flexibly connected to one another by intermediate connectors that allow heat exchanger fluid to flow between the plates and are flexible to allow the adjacent heat exchanger plates to be compressed towards each other after the introduction of battery modules between the heat exchanger plates, wherein the intermediate connectors are designed to snap into a compressed state after a compression threshold is reached.

[0009] According to one embodiment, a heat exchanger for exchanging thermal energy with battery modules is provided, comprising several heat exchanger plates, each defining an internal fluid flow passage for a heat exchanger fluid, and arranged in a stack in which adjacent heat exchanger plates are spaced apart, wherein the adjacent heat exchanger plates each comprise a main plate section and an inlet plate and an outlet plate connected to the main plate section and defining an inlet fluid passage and an outlet fluid passage that communicate with the internal fluid passage, and each of the plates is flexibly connected to the main plate section such that the main plate section can be displaced relative to the plates.the inlet and outlet panels of at least some of the heat exchanger plates are connected to the inlet and outlet panels of adjacent heat exchanger plates to form a stack of substantially parallel heat exchanger plates spaced apart from each other, and the main plate sections are movable relative to their respective inlet and outlet panels at least prior to the introduction of battery modules between the heat exchanger plates.

[0010] According to one embodiment, a battery unit is provided which includes a first battery module with at least one battery cell; and a heat exchanger plate adjacent to the battery module and with a surface in thermal contact with the first battery module, wherein the heat exchanger plate has a compliant area which is deformable in response to a force exerted on the heat exchanger by the battery module.

[0011] According to another embodiment, a heat exchanger for exchanging thermal energy with battery modules comprises: several heat exchanger plates, each defining an internal fluid flow passage for a heat exchanger fluid, arranged in a stack in which adjacent heat exchanger plates are spaced apart, and the adjacent heat exchanger plates are flexibly connected to each other to allow parallel movement of adjacent heat exchanger plates during compression, thus ensuring good thermal contact between the heat exchanger plates and the battery modules. In some examples, adjacent heat exchanger plates are connected to each other by protruding projections, the projections being compressible. Brief description of the drawings Fig. Figure 1 is a schematic perspective view of a battery unit according to an exemplary embodiment. Fig. 2 is an enlarged front view showing part of three adjacent battery cell containers from one of the battery modules of the battery unit. Fig. 1 illustrated. Fig. Figure 3 is a perspective view of a fluid-cooled heat exchanger according to an exemplary embodiment. Fig. Figure 4 is a top view of the heat exchanger according to Fig. 3. Fig. Figure 5 is a sectional view of the heat exchanger along line VV in Fig. 4. Fig. Figure 6 is an enlarged view of area 6 in Fig. 5. Fig. Figure 7 is a split view of a flow chamber area in Fig. 6. Fig. Figure 8 is a perspective view of an inner core plate of the heat exchanger according to Fig. 3. Fig. Figure 9 is a perspective view of an outer core plate of the heat exchanger according to Fig. 3. Fig. Figure 10 is a top view of a first sealing plate of the heat exchanger according to Fig. 3. Fig. 11 is a top view of a second sealing plate of the heat exchanger according to Fig. 3. Fig. Figure 12 is a perspective view of a fluid-cooled heat exchanger according to another embodiment. Fig. 13 is a top view of one side of the heat exchanger according to Fig. 12. Fig. Figure 14 is a top view of the opposite heat exchanger according to Fig. 12. Fig. Figure 15 is a sectional view of the heat exchanger along line XV-XV in Fig. 14. Fig. 16 is a top view of a first core plate of the heat exchanger according to Fig. 12. Fig. 17 is a top view of a second core plate of the heat exchanger according to Fig. 12. Fig. 18 is a sectional view of the second core plate along line XVIII-XVIII in Fig. 17. Fig. Figure 19 is a top view of a flexible plate of the heat exchanger according to Fig. 12. Fig. Figure 20 is a sectional view of the flexible plates along line XX-XX in Fig. 19. Fig. Figure 21 is an enlarged sectional view of part of a compliant plate structure of the heat exchanger according to Fig. 12. Fig. Figure 22 is an end view of a battery unit according to a further embodiment. Fig. Figure 23 is an enlarged sectional view along line AA in Fig. 22. Fig. Figure 24 is a perspective view of a battery module of the heat exchanger according to Fig. 22. Fig. Figure 25 is a perspective view of part of the heat exchanger according to Fig. 22. Fig. Figure 26 illustrates various configurations of compliant protrusions that are used in the heat exchanger according to Fig. 22 can be applied. Fig. Figure 27 is a partially perspective view of another embodiment of a heat exchanger. Fig. Figure 28 is a partially perspective view of a plate of the heat exchanger according to Fig. 27. Fig. Figure 29 is a top view of a battery unit that connects the heat exchanger to the heat exchanger. Fig. Contains 27. Fig. 29A, Fig. 29B and Fig. Figure 29C shows top views of various embodiments of a heat exchanger. Fig. 30 is a sectional view of the battery unit after Fig. 29 along line XXX-XXX in Fig. 29. Fig. 31 is another sectional view of the battery unit after Fig. 30 along line XXXI-XXXI to Fig. 29 Fig. 32A and Fig. 32 B are each enlarged partial sectional views (from a similar perspective as in Fig. 23), which illustrate a further embodiment of a heat exchanger, which includes branch connectors between compliant raised areas of adjacent heat exchanger plates. Fig. Figure 33 is an enlarged partial sectional view (from a similar perspective to that in Fig. 23), which illustrates a further embodiment of a heat exchanger incorporating a two-piece flexible branch connector between adjacent heat exchanger plates. Fig. Figure 34 is a schematic sectional view, which further shows a flexible branch connector of the heat exchanger to Fig. 33 illustrated. Fig. Figure 35 is a front view of the flexible branch connector according to Fig. 34. Fig. 36A, Fig. 36B and Fig. Figure 36C shows views of a further embodiment of a two-piece flexible branch connector used in the heat exchanger according to Fig. 33 can be applied, whereby Fig. 36A is a top view, Fig. 36B a sectional view along line AA in Fig. 36A is, and Fig. Figure 36C is a perspective view. Fig. Figure 37 is a sectional view of yet another embodiment of a two-piece flexible branch connector, which is used in the heat exchanger according to Fig. 33 can be applied. Description of the exemplary implementations

[0012] Reference will now be made in detail to specific implementations of the technology. Each example is provided solely for the purpose of illustrating the technology, not as a limitation of the technology. It is evident to the person skilled in the art that various modifications and changes can be made within the present technology. For example, features described as part of one implementation of the technology can be used for another implementation to result in yet another implementation. Thus, the present technology is intended to cover such modifications and changes that fall within the scope of the technology.

[0013] Fig. Figure 1 shows an illustrative example of a rechargeable battery unit 100 according to embodiments of the invention. The battery unit 100 consists of battery stacks or modules 102(1) and 102(2) (here generally referred to as 102(i)), which in turn consist of battery cell containers 104, each of which accommodates one or more battery cells 106. The illustrated embodiment includes two rectangular, box-like modules 102(i), each of which consists of six horizontally arranged cell containers 104, each cell container 104 accommodating one or more battery cells 106.The number of modules 102(i) in the battery unit 100, the number of cell containers 104 in each module 102 and the number of battery cells 106 in each battery cell container 104 may vary, and the orientation and shape of these components may also vary from application to application, and accordingly the quantities and orientations in this description are provided only as an example of an illustrative embodiment.

[0014] In at least some embodiments, the battery cells 106 are lithium-ion battery cells; however, other rechargeable battery cells can be used. In some embodiments, the battery cells 106 are prismatic lithium-ion battery cells. In other embodiments, the battery cells 106 have cylindrical or other shapes. In the illustrated embodiment, each battery cell container 104 comprises a rectangular, substantially rigid, box-like housing that accommodates one or more battery cells 106. In some embodiments, all the cell containers 104 within a module 102(i) are substantially identical, and the modules 102(i) that form a battery unit 100 are substantially identical. In embodiments, the battery modules 102(i) can be mounted side by side or one above the other in a support frame or rack 108.In some embodiments, the battery cell containers 104 may not be rigid.

[0015] According to exemplary embodiments, a heat exchanger 110 is located between opposing surfaces 112 and 113 of adjacent battery modules 102(1) and 102(2). The contact surfaces 112 and 113 between the respective modules 102(1) and 102(2) and the heat exchanger 110 located between them need not be perfectly flat surfaces, and they may still be warped due to expansion and contraction during heating and cooling. (Illustrated by way of example) Fig. 2 a contact surface 112 defined by heat exchanger contact faces 114 of three adjacent battery cell containers 104 in the upper module 102(1). As a consequence of manufacturing tolerances of the cell containers 104 as well as module assembly tolerances, the cell containers 104 cannot be perfectly identical or perfectly aligned. As a consequence, the heat exchanger contact faces 114 are not aligned, resulting in a heat exchanger contact surface 112 that is not flat but instead contains small height transitions at the boundaries between adjacent cell containers 104. As in Fig. As shown in Figure 2, “T” represents a maximum displacement tolerance between the heat exchanger contact faces 114 of the cell containers 104 in a module 102. As a non-limiting example, the tolerance T may be in the range of 0.5 mm to 1 mm for some applications, but the tolerance may also be outside this range for some applications.

[0016] Accordingly, a heat exchanger 110 that can maintain uniform contact with the geometry of the cell containers 104 between adjacent modules 102(i) over a range of temperatures and contact surface tolerances, and that provides good thermal conductivity, is desirable in some applications. In this respect, exemplary embodiments relate to a heat exchanger structure that is dimensionally flexible in order to maintain contact with battery cell containers 104 via the battery unit 100, even if the battery cell containers do not define a flat heat exchanger contact surface.In some examples, the dimensionally flexible heat exchanger 110 is compressed under the expansion of the first and second battery modules, and expands under the subsequent contraction of the first and second battery modules, such that the heat exchanger structure remains in thermal contact with the battery cell containers 104 over a range of normal battery operating temperatures.

[0017] In the Fig. 3 and Fig. In one embodiment, the heat exchanger 110 is a multi-pass plate-type heat exchanger, which defines an internal helical heat exchanger fluid flow passage 118 with a first end in fluid connection with an inlet fitting 120 and a second end in fluid connection with an outlet fitting 122. In the illustrated example, the helical fluid flow passage 118 contains several parallel fluid chambers 116(1) - 116(6) connected in series (here generally referred to by the use of reference numeral 116(i) and by dashed lines in the figure). Fig. (3 shown), wherein each fluid chamber is connected to a subsequent fluid chamber by a respective, substantially U-shaped flow passage 126. During operation, a heat exchange fluid, such as a cooling fluid, enters the fluid inlet fitting 120, flows through fluid chamber 116(1), through a first U-shaped passage 126 into fluid chamber 116(2), and then through a second U-shaped passage 126 into fluid chamber 116(3), and so on, until the fluid flows through the last fluid chamber 116(6) and exits through the outlet fitting 122. The heat exchange fluid flowing through the inner flow passage 118 can, for example, be a cooling fluid such as water or another liquid, or a gaseous refrigerant for extracting heat from the battery cell containers 104.In some embodiments, the heat exchanger fluid passing through the inner flow passage 118 can be a heating fluid for heating the battery cell containers 104.

[0018] As schematically in Fig. As shown in Figure 1, in one embodiment, each fluid chamber 116(i) is positioned between a cell container 104 located in module 102(1) and an opposing cell container 104 located in the adjacent module 102(2). In the illustrated example, the heat exchanger contains six parallel fluid chambers 116(1) - 116(6), with each fluid chamber 116(i) being located between opposing pairs of battery cell containers 104 in the battery unit 100. However, the number of fluid chambers can be less than or greater than six, depending on the specific application. In some embodiments, the U-shaped areas defining the U-shaped passages 126 are free and extend outwards beyond the sides of the battery modules 102(1), 102(2) such that the U-shaped passages 126 are not positioned between the battery cell containers 104.In some embodiments, the U-shaped areas are not exposed and are positioned between the battery modules 102(1) and 102(2). The fluid chambers 116(1) to 116(6) are each formed within a respective fluid chamber area 124(1) to 124(6) (here generally referring to the use of the reference number 124(i)) of the heat exchanger 110. As will be explained in detail below, in some embodiments, each of the fluid chamber areas 124(i) can be individually adjusted independently of the other fluid chamber areas 124(i) of the heat exchanger 110, such that deviations from opposing surfaces 112 and 113 of the cell containers between the adjacent modules 102(1) and 102(2) can be accommodated by the heat exchanger 110.

[0019] In the sectional views of the in the Fig. In one embodiment of the heat exchanger 110 shown in Figures 5-7, the body of the heat exchanger 110 is formed from six stacked plates, namely the first and second outer cover plates 128, 130; the first and second outer core plates 132, 134; and the first and second inner core plates 136, 138. In one embodiment, the plates are each formed from coil-formed or stamped aluminum or an aluminum alloy and are brazed together to form the body of the heat exchanger 110. However, the heat exchanger can alternatively be formed from other elastic metals or materials, including plastics, and through other processes.

[0020] In one embodiment, the first and second inner core plates 136 and 138 are essentially identical, and in this respect shows Fig. Figure 8 shows a perspective view of an example of an inner core plate 136, 138. The inner core plate 136, 138 contains a rectangular flat plate area 140 with a raised serpentine projection 142 formed on it. The serpentine or coiled projection 142 is adapted to the shape of the inner flow passage 118 and contains parallel inner core plate areas 143(1) - 143(6) (generally designated by reference numeral 143(i)), which correspond to the respective flow chamber areas 124(1) - 124(6). A coiled slot 144 is provided along the length of the coiled projection 142. The slot 144 terminates in an enlarged inlet or outlet opening 146, 148 at its opposite ends.

[0021] In one embodiment, the first and second outer core plates 132 and 134 are also essentially identical, and in this respect shows Fig. Figure 9 shows a perspective view of an example of an outer core plate 132, 134. The outer core plate 132, 134 is a serpentine or coiled part adapted to the shape of the inner flow passage 118. The core plate 132, 134 contains parallel core plate regions 154(1) - 154(6) (generally designated by reference numeral 154(i)) connected in series, corresponding to the respective flow chamber regions 142(1) - 124(6). Adjacent core plate regions 154(i) are connected by substantially U-shaped regions 156 at alternating ends of the plate 132, 134. The configuration of the core plate 132, 134 allows a degree of physical isolation between each of the core plate regions 154(i), such that each of the core plate regions 154(i) can be elastically compressed independently of the other core plate regions 154(i). A coiled slot 149 is provided along the core plate 132, 134 and terminates in an enlarged inlet or outlet.Outlet opening 150, 152 at its opposite ends.

[0022] Fig. Figure 10 is a top view of an example of a substantially planar first cover plate 128. The first cover plate 128 is also a coiled part adapted to the shape of the inner flow passage 118. The cover plate 128 contains parallel first cover plate sections 158(1) - 158(6) (generally referred to by reference numeral 158(i)) connected in series, corresponding to the respective flow chamber sections 124(1) - 124(6). Adjacent first cover plate sections 158(i) are connected by substantially U-shaped sections 160 at alternating ends of the plate 128. The configuration of the first cover plate 128 allows a degree of physical insulation between each of the first cover plate areas 158(i) such that each of the cover plate areas 158(i) can be offset towards the center of the heat exchanger body independently of the other cover plate areas 158(i).Enlarged inlet and outlet openings 162, 164 are provided at opposite ends of the coiled cover plate 128.

[0023] Fig. Figure 11 is a top view of an example of a substantially planar second cover plate 130. The second cover plate 130 is a coiled part that is substantially identical to the first cover plate 128, except that the second cover plate does not include the inlet and outlet openings 162, 164. The same reference numerals are used in the figures for similar elements in the cover plates 128 and 130.

[0024] The characteristics of plates 128, 130, 132, 134, 136 and 138 and their composition will now be described in detail with reference to the sectional views of the Fig. 6 and Fig. 7 explained. In the heat exchanger 110, the inner core plates 136 and 138 are connected facing each other, their respective flat plate areas 140 being in contact with each other and their respective raised areas 142 extending away from a center line C of the heat exchanger body. For the purposes of explanation, the term "inner" used here indicates a direction towards the center line C, and the term "outer" indicates a direction away from the center line C, unless the context means otherwise. The raised area 142 of the first inner core plate 136 and the second inner core plate 138 are aligned with each other to partially define the inner tortuous flow passage 118. As from Fig. As can be seen in Figure 7, the raised area 142 of the first and second inner core plates 136, 138 is formed by opposing side walls 166 extending away from the flat plate area 140 and each terminating at a flat flange 168 that defines the coiled slot 144. The flat flanges 168 are substantially parallel to the flat plate area 140. In one embodiment, each side wall 166 has a first arcuate wall section 170 that is curved outwards relative to the center line C, and a second arcuate wall section 172 that is curved inwards relative to the center line C, thus providing the side wall 166 with a profile that is approximately an "S" shape.In some exemplary configurations, such a sidewall profile provides the raised projection 142 with a degree of elastic adaptability such that the projection 142 can be deformed towards the centerline C under compression and then spring back to a normal shape when the compression is removed. The generally S-shaped sidewall profile can disperse stresses in some embodiments, thus reducing fatigue; however, other sidewall configurations can alternatively be used to reduce fatigue.

[0025] The first outer core plate 132 and the second outer core plate 134 are secured on opposite sides of the centerline C to the first inner core plate 136 and the second inner core plate 138, respectively. Each coiled outer core plate 132, 134 defines a coiled channel 174 that opens outwards relative to the centerline C and forms part of the inner coiled flow passage 118. In particular, the channel 174 is defined by a pair of opposing side walls 176. The side walls 176 each extend from an outer planar circumferential flange 178 to an inner planar flange 180, the outer flange 178 and the inner flange 180 having substantially parallel, opposing surfaces.In the illustrated embodiment, each side wall 176 has a first arcuate wall section 182 that is curved outwards relative to the center line C, and a second arcuate wall section 184 that is curved inwards relative to the center line C, thus providing the side wall 176 with a profile that generally approximates an "S" shape. In one example, the inner flanges 186 each terminate at an inwardly extending lip 186, with the lip 186 on one flange 180 facing the lip 186 on the other flange 180 to define the winding slot 149.

[0026] The inner flanges 180 of the first outer core plate 132 are paired with respective flat areas 168 of the first inner core plate 136 to secure the first outer core plate 132 to the first inner core plate 136. As shown in the Fig. 6 and Fig. As illustrated in Figure 7, the coiled slot 149 of the outer core plate is aligned with the coiled slot 144 of the inner core plate, with the opposing lips 186 of the outer core plate extending into the coiled slot 144 of the inner core plate. The positioning of the lips 186 of the outer core plate within the slot 144 of the inner core plate results in a mechanical interlock between the inner and outer core plates, which strengthens the connection between them and also helps to provide a seal against interplate leakage. Furthermore, it can aid in aligning the plates during heat exchanger assembly. In some configurations, the positioning of the lips 186 of the outer core plate within the slot 144 of the inner core plate can act as a limit to the extent to which the flow chamber region 124(i) can be deformed.In some embodiments, other deformation limiting features may be provided in different areas of the heat exchanger body to limit the deformation of such areas. The second outer core plate 134 is secured to the second inner core plate 138 in a similar manner to how the first outer core plate 132 is secured to the first inner core plate 136. In some embodiments, the interlocking between the inner and outer core plates may be reversed, with the lips 186 being provided on the inner core plate instead of the outer core plate and then inserted into the slot 149 in the outer core plate.

[0027] In some embodiments, the generally S-shaped profile of the side walls 176 of the outer core plate 132, 134 imparts a degree of elastic adaptability to the outer core plates 132, 134 such that the outer core plates can be deformed under compression towards the centerline C and then spring back to a normal shape when the compression is removed. In some embodiments, the generally S-shaped side wall profile can disperse the stress in such a way as to reduce fatigue; however, other side wall configurations can alternatively be used to reduce fatigue.

[0028] In the illustrated embodiment, the coiled first outer cover plate 128 is attached to an outer side of the coiled first outer core plate 132 to seal the first outer core plate channel 174. The cover plate sections 158(i) and the U-shaped sections each contain a flat central section 188 with inwardly directed flanges 190 along its opposite circumferential edges. Circumferential sections of the flat central section 188 are mated with the flat outer flanges 178 of the first outer core plate 132, the flat outer flanges 178 being received in the inwardly directed flanges 190 of the first outer cover plate 128. The coiled second outer cover plate 130 is attached in a similar manner to an outer side of the coiled second outer core plate 134 to seal the second outer core plate channel 174.In some embodiments, the inwardly directed flanges 190 can help to position the cover plates during assembly, and they can also have a deflection or deformation limiting effect on the flow chamber areas. In the illustrated embodiment of the heat exchanger 110, the inlet openings 146 of the inner core plates 136, 138, the inlet openings 150 of the outer core plates 132, 134, and the inlet opening of the outer cover plate 128 are aligned with each other to form a fluid inlet for the inner flow passage 118 of the heat exchanger, with the inlet fitting 120 being attached to the outer cover plate 128.Similarly, the outlet openings 148 of the inner core plates 136, 138, the outlet openings 152 of the outer core plates 132, 134, and the outlet opening of the outer cover plate 128 are aligned with each other to form a fluid outlet for the inner flow passage 118 of the heat exchanger, with the outlet fitting 122 attached to the outer cover plate 128. The second cover plate 130 seals the fluid inlet and fluid outlet of the heat exchanger on the side of the heat exchanger opposite the side where the inlet and outlet fittings 120, 122 are located. According to . Fig. In the embodiment described here, each fluid chamber 116(i) of each fluid region 124(i) contains three communicating flow regions, namely the channel 174 defined by the first cover plate 128 and the first outer core plate 132, the channel 174 defined by the second cover plate 130 and the second outer core plate 134, and the central channel 192 defined between the inner core plates 136, 138. As a consequence of the slots 144, 149, the channels 174, 192 are in fluid communication along the entire length of the coiled flow passage 118.

[0029] The flat central areas 188 of the inner and outer cover plates 128, 130 form a physical interface with the battery cell containers 104 of the battery unit 100. Thus, in one embodiment, each fluid chamber area 124(i) of the heat exchanger 110 has an elongated area 158(i) of the first cover plate that engages with a respective battery cell container 104 in the first battery module 102(1), and an elongated area 158(i) of the second cover plate that engages with a respective battery cell container 104 on the opposite side of the heat exchanger in the second first battery module 102(1). In this respect, each fluid chamber area 124(i) of the heat exchanger 110 is mounted between a pair of opposing battery cell containers 104 and forms heat exchange surfaces with them.As can be seen from the preceding description, the side walls 176 of the outer core plates 132, 134 and the side walls 166 of the inner core plates 136, 138 are designed such that they provide elastic compressibility of each of the parallel fluid chamber regions 124(i). Furthermore, physical separation by elongated slots 194 (see, for example, ) enables Fig. 5) between the parallel areas 154(i) of the outer core plates 132, 134 and the fluid chamber areas 124(i), each be individually compliant with respect to the physical separation between the two battery cell containers 104, such that the fluid chamber area 124(i) is located between them. The pressure of the heat exchanger fluid within the flow chambers 116(i) can cause the compressibility of the fluid flow areas 124(i) in some embodiments.

[0030] By way of non-limiting examples, in some applications the plates used to form the heat exchanger 110 may be made of H3534 aluminum brazing sheet and / or 3003 aluminum. Alternative plate configurations may be used to achieve similar results—for example, fewer than six plates may be used to form a heat exchanger with individually compliant flow regions.

[0031] The Fig. Figures 12-15 show another example of a heat exchanger 210, which can be used as an alternative to the heat exchanger 110 in some applications. The heat exchanger 210 is similar to the heat exchanger 110 in function and design, except for differences that are apparent from the figures and the following description. In one embodiment, the heat exchanger 210 includes a substantially rigid core plate structure 228, which is clamped between substantially planar first and second compliant plate structures 230. In other embodiments, the compliant plate structures 230 are each designed to be elastically deformable such that the heat exchanger 210 is compliant in its dimensions with respect to the space between the first battery module 102(1) and the second battery module 102(2).The core plate structure 228 of the heat exchanger 210 defines an internal helical heat exchanger fluid flow passage 218 with a first end in fluid communication with an inlet fitting 220 and a second end in fluid communication with an outlet fitting 222. In the illustrated example, the helical fluid flow passage 218 contains several parallel fluid chambers 216(1) - 216(6) connected in series (here generally designated by using the reference number 216(i) - see ). Fig. 15), wherein each fluid chamber is connected to a subsequent fluid chamber by a substantially U-shaped flow passage 226. During operation, a heat exchange fluid, such as a cooling fluid, enters the fluid inlet fitting 220, flows through the fluid chamber 216(1), through a first U-shaped passage 226 into the fluid chamber 216(2), and then through a second U-shaped passage 226 into the fluid chamber 216(3), and so on, until the fluid flows through the last fluid chamber 216(6) and exits the outlet fitting 222.

[0032] As in the heat exchanger 110, in one embodiment each fluid chamber 216(i) of the heat exchanger 210 is positioned between a cell container 104 located in a module 102(1) and an opposing cell container 104 located in the adjacent module 102(2).

[0033] The fluid chambers 216(1) - 216(6) are each formed within a respective fluid chamber area 224(1) - 224(6) (here generally referred to by the reference number 224(i)) of the core plate structure 228 of the heat exchanger 210.

[0034] According to the in Fig. In the sectional views of the heat exchanger 210 shown in Figure 15, the heat exchanger core plate structure 228 is formed from opposing first and second core plates 232, 234; and the first and second flexible plate structures 230 are each formed from opposing flexible plates 236. In one embodiment, the plates are each formed from coil-formed or stamped aluminum or an aluminum alloy and are brazed together to form the body of the heat exchanger 210. However, the heat exchanger can alternatively be formed from other elastic metals or materials, including plastics, and by other processes.

[0035] In one embodiment, the first and second core plates 232 and 234 are essentially identical, and in this respect the Fig. 16 and Fig. 17 Top views of examples of core plate 234 and 232. Core plates 234 and 232 each contain a rectangular flat plate area 240 with a raised, coiled projection 242 formed on it. The coiled projection 242 is adapted to the shape of the inner flow passage 218 and contains parallel core plate areas 243(1) - 243(6) (generally designated by reference numeral 243(i)), which correspond to the respective flow chamber areas 224(1) - 224(6). One difference between the first core plate 232 and the second core plate 234 is that an inlet and an outlet opening 246, 248 are formed at opposite ends of the raised projection 242 of the first core plate 232.

[0036] In one embodiment, the first and second compliant plates 236, which form the compliant plate structures 230, are essentially identical, and in this respect the Fig. 19 and Fig. Figure 20 shows an example of a compliant plate 236. In the illustrated example, the compliant plate 236 is a rectangular plate containing several raised, parallel, elongated projections 250 separated by slots 252 extending through the plate. Fig. Figure 21 is an enlarged partial sectional view showing two compliant plates 236 paired opposite each other to form a compliant plate structure 230. As shown in the figure. Fig. As can be seen from Figure 21, each of the elongated projections 250 contains a flat central wall bounded by side walls 256, each terminating at a flat circumferential flange 258. The flanges 258 of one flexible plate 236 are paired with the flanges 258 of the opposite flexible plate 236 to form the flexible plate structure 230. As shown from Fig. As can be seen in Figure 21, the opposing protrusions 250 of the paired compliant plates 236 define inner chambers 260 such that the paired compliant plates 236 define several parallel, elongated compliant chamber regions 262(1) - 262(12) (here generally referred to as 262(i)). In one embodiment, the chambers 260 are sealed chambers filled with a fluid or gas such as air or a non-fluid thermal sealant. In another embodiment, the chambers 260 can be vented. In the illustrated embodiment, the compliant plate structure 230 contains twelve elongated compliant regions 262(i), two for each of the six flow chamber regions 224(i) of the core plate structure 228.

[0037] In one embodiment, the compliant areas 262(i) ​​of the compliant plate structure 230 are each individually deformable in such a way that each of the compliant areas 262(i) ​​can be individually compressed up to a threshold amount under an external pressure and then spring back to its initial shape when the pressure is removed.

[0038] In some embodiments, the flexible plates 263 are made of thinner material than the core plates 232, 234, with the result that the core plate structure 228 is relatively rigid compared to the flexible plate structures 230 sandwiched between them. In a non-restrictive example, the flexible plates 236 can be made of aluminum with a thickness of 0.2 mm and the core plates 232, 234 of aluminum with a thickness of 0.6 mm; however, many alternative thicknesses can be used.

[0039] According to the Fig. In the heat exchanger 210, a first and a second core plate 232, 234 are connected facing each other, their respective flat plate areas 240 being in contact with each other and their respective raised areas 242 extending away from each other to define the inner helical multipath heat exchanger fluid flow passage 218. Flexible plate structures 230 are provided on the opposite faces of the core plate structure 228 to provide an interface with the first battery module 102(1) and the second battery module 102(2), respectively. In the illustrated embodiment, a pair of parallel, elongated flexible chambers 262(i), 262(i+1) extend along the length of each fluid chamber area 224(i) on each side of the core plate structure 228.The compliant chambers 262(i) ​​and 262(i+1), located on opposite sides of each fluid chamber area 224(i), allow each of the fluid chamber areas to be individually compliant for physical separation between the two battery cell containers 104, such that the fluid chamber area 124(i) is located in between.

[0040] Accordingly, in the exemplary embodiments of the Fig. Figures 1 to 21 describe a heat exchanger 110, 210 arranged between two battery modules 102(1) and 102(2), each containing several battery cell containers. In some applications, the surfaces of the battery modules 102(1) and 102(2) that contact opposite sides of the heat exchanger 110, 210 need not be perfectly flat due to a lack of perfect alignment of the battery cell containers forming the battery modules 102(1) and 102(2). Thus, in at least some embodiments, to help maintain contact between the battery module surfaces and the opposite sides of the heat exchanger 110, 210, the heat exchanger 110, 210 includes independently adjustable areas, each of which has a spring action such that each adjustable area corresponds to a respective pair of opposite battery cell containers and can flex adaptably under the compression forces exerted on the area.Accordingly, in at least some embodiments, when a battery unit is mounted which contains battery modules 102(1), 102(2) and heat exchangers 110, 120, a compression effect occurs, while the areas of the heat exchanger 110 are subjected to a degree of compression to facilitate good thermal contact between the battery modules 102(1), 102(2) and the heat exchanger 110, 120.

[0041] In some embodiments, the previously described adaptable heat exchanger configurations can be used between fuel cell modules instead of battery cell modules.Accordingly, the heat exchanger structures described here can be used in a power generation unit comprising a first module with multiple power generation cells such as battery cells or fuel cells and a second module with multiple power generation cells such as battery cells or fuel cells, wherein the heat exchanger structure is arranged between opposing surfaces of the first stack and the second stack and defines one or more fluid flow passages, the heat exchanger structure is dimensionally flexible to adapt to different separation distances between opposing cells within the battery unit, and in some embodiments is dimensionally flexible to be compressed when the first and second stacks expand and to expand when the first and second stacks subsequently contract.In some embodiments, an intermediate material or structure can be arranged between the outer cover plates and the battery cell containers 104 to increase thermal conductivity and to compensate for irregularities in the surface profiles of the individual battery cell containers.

[0042] In exemplary embodiments, the previously described adaptable heat exchanger 110 contains compliant regions over substantially the entire fluid flow path defined by the heat exchanger. In some exemplary embodiments, the compliance of the heat exchanger can be more localized. In this respect, the Fig. 22-25 A battery unit 300 comprising a heat exchanger 302 with localized compliant areas according to further embodiments, as detailed below. The battery heat exchanger 302 comprises several (N) substantially identical, spaced-apart heat exchanger modules or plates 306(1) to 306(N) (here generally referred to by reference numeral 306) arranged substantially in a row or column. The battery unit 300 comprises battery modules 304(1) to 304(N-1) (generally referred to by reference numeral 304) nested with the heat exchanger plates 306(1) such that at least one battery module 304 is located between and in thermal contact with the opposing surfaces of two adjacent heat exchanger plates 306.

[0043] Fig. Figure 25 schematically illustrates three heat exchanger plates 306(1), 306(2) and 306(3) of the heat exchanger 302, and Fig. Figure 24 schematically illustrates a battery module 304, which can be arranged, for example, between heat exchanger plates 306(1) and 306(2) or between heat exchanger plates 306(2) and 306(3). In the illustrated embodiments, the heat exchanger plates 306 and the battery modules 304 have a rectangular plan or profile; however, they can have other shapes in other embodiments, such as square or circular. Each battery module 304 accommodates at least one battery cell, which can be, for example, a prismatic lithium-ion battery cell (however, other rechargeable battery cells can be used). In the illustrated embodiment, each battery module 304 includes a rectangular, substantially rigid housing or frame that accommodates the one or more battery cells.

[0044] As from Fig. 23 and Fig. As can be seen in Figure 25, in one embodiment the heat exchanger plates 306 each define several internal fluid flow paths or passages 308 (in Fig. (25 shown in dashed lines) between a fluid inlet 310 and a fluid outlet 312. In the illustrated embodiment, each plate 306 contains several substantially parallel, C-shaped internal flow passages 308; however, many different fluid flow path configurations are possible, including, for example, a single helical flow path between the inlet 310 and the outlet 312. In one embodiment, the fluid inlet 310 of all plates 306 is connected to a common fluid inlet multiplier 314, and the fluid outlets 312 are all connected to a common fluid outlet multiplier 316. During operation, a heat exchange fluid is distributed to each of the heat exchanger plates 306 via the inlet multiplier 314 and collected by the heat exchanger plates 306 via the outlet multiplier 316.In some embodiments, the fluid passing through the inner flow passages 308 is used to cool the heat exchanger plates 306 and the battery modules 304 located between them, although in some embodiments the fluid passing through the inner flow passages 308 is used to heat the heat exchanger plates 306 and the battery modules 304 during at least some parts of the battery operation.

[0045] In one embodiment, each heat exchanger plate 306 is formed from a pair of mutually adapted, substantially identical first and second plate parts 318, 320, as best seen from the Fig. 22 and Fig. As can be seen in Figure 23. In the illustrated embodiment, the first plate part 318 and the second plate part 320 are each substantially flat parts with external, mutually facing grooves 322, which interact to define internal fluid flow passages 308. Furthermore, the plate parts 318, 320 each contain a pair of outwardly extending bubbles or protrusions 324 and 326, each defining a respective flow opening 328. The protrusions 324 of the first and second plate parts 318, 320 of each heat exchanger plate 306 are aligned with each other to form the plate inlet 310, and the protrusions 324 of all plates 306 are aligned in fluid contact with each other to form the inlet fluid multiplier 314 and the heat exchanger 302.Similarly, the protrusions 326 of the first and second plate parts 318, 320 or of each heat exchanger plate 306 are aligned with each other to form the plate outlet 310, and the protrusions 326 of all plates 306 are designed in fluid communication with each other to form the outlet fluid multiplier 316 for the heat exchanger 302.

[0046] In exemplary embodiments, the first and second plate parts 318, 320 are formed from aluminum alloy or stainless steel or other sheet material coated with brazing alloy; however, in some exemplary embodiments, plastic or other synthetic materials can be used. The protrusions 324, 326 can be formed, for example, by deep-drawing areas of the sheet material. In some exemplary embodiments, the areas of sheet material in which the protrusions 324, 326 are to be formed can be made of thicker material to provide a material suitable for deep-drawing the protrusions. For example, a custom-tailored patch can be applied to the area of ​​the protrusions before the plates are formed.

[0047] In some embodiments, the heat exchanger 302 is pre-assembled as a unit, joined together by brazing, and then the battery modules 304 are inserted between the heat exchanger plates 306. In the illustrated embodiment, the inlet and outlet multipliers 314, 316 are each located on the same side of the heat exchanger 302 to facilitate the lateral insertion of the battery modules 304 from the opposite side of the heat exchanger 302.

[0048] According to exemplary embodiments, the projections 324, 326 are flexible so that they can be compressed axially after the battery modules 304 are inserted to establish thermal contact between the battery modules 304 and the heat exchanger plates 306. In some exemplary embodiments, such a configuration can allow a pre-compression gap, which facilitates the insertion of the battery modules 304 during assembly, while maintaining close thermal contact between the heat exchanger plates 306 and the battery modules 304 after compression.Additionally, in some configurations, the compliant nature of the protrusions 324, 326 can allow the multipliers 314, 316 of the heat exchanger 302 to expand and contract effectively during battery operation in response to expansion and contraction forces exerted by the battery modules as they heat up and cool down, thereby facilitating good thermal contact between the heat exchanger plates 308 and the battery modules 304 over a range of operating temperatures.

[0049] Thus, with reference to Fig. 23 the bubble or elevation height “H” of an elevation 326 a pre-assembly height before the battery modules 304 are inserted, of H=X, and a post-assembly height of H=Y, where Y <X; während der Montage, nachdem die Batteriemodule 305 eingeführt wurden, wird der Wärmetauscher 302 zusammengedrückt, wodurch die Erhebungshöhen auf H=Y verringert werden. Bei dem Ausführungsbeispiel nach Fig. 23 Each annular projection is formed from an axially extending first annular wall 330, which terminates at a radially extending first annular shoulder 332, which in turn terminates at an axially extending second annular wall 334, which in turn terminates at a radially extending second annular shoulder 336, defining the opening 328. The shoulder 332 forms a supporting element that imparts compliance to the projection 326 such that the elastic nature of the projection 326 is largely a function of the width or diameter D of the first annular shoulder and the thickness and elasticity of the material forming the projection 326. In one embodiment, the projection 326 has a substantially linear force deflection curve when it is displaced between H=X and H=Y. The inlet projection 324 is substantially identical to the outlet projection 326.

[0050] In another embodiment, the projection 326 is designed to produce a "snap-through effect" by which it is pre-tensioned to H=X for a certain range of axial compression, then pre-tensioned to H<=Y after the degree of axial compression has passed a threshold value. In this respect, the Fig. 26 at (A) a protrusion 324, 326 which is pre-tensioned in a pre-assembly position (before the insertion of battery modules) in which H=X, and at (B) the same protrusion 324, 326 which is pre-tensioned in a “packaging” or post-assembly position (after the insertion of battery modules 304 into the heat exchanger 302) in which H<=Y <X. In der Erhebung 324, 326, nachdem der Auslenkungswinkel der Schulter 332 einen Schwellenwert passiert, findet ein „Durchschnappen“ der Erhebung in ihre Nachmontageposition statt. Bei einigen Beispielen spannen, nachdem die Schwellenwertauslenkung erreicht ist, die Erhebungen der gegenüberliegenden Platten 306 die Platten zu einer Interplattentrennung vor, die kleiner als die Batteriemodulhöhe in der Weise ist, dass die Platten 306 wirksam die gegenüberliegenden Oberflächen des Batteriemoduls 304 festklemmen, um einen thermischen Kontakt mit dem Batteriemodul über einen Bereich von normalen Betriebstemperaturen der Batterieeinheit 300 beizubehalten.As in . Fig. As illustrated in (C) for some embodiments, the compliance of protrusions 324, 326 depends on the shoulder dimension L and the thickness of the material used to form the plates.

[0051] As in Fig. As shown in Figure (D) 26, in some embodiments a bellows-like structure 325 can be formed on the projections 324, 326 of one or both core plates to provide the projections 324, 326 with a degree of elastic compressibility. The degree of compliance again depends on the dimension L and the thickness of the material used to form the plates.

[0052] Accordingly, the compressible protrusions 324, 326 of the heat exchanger 302 result in a localized compliance in the area of ​​the heat exchanger multipliers.

[0053] According to another embodiment, a further configuration consisting of a battery unit 400 and a heat exchanger 402 is described with reference to the Fig. 27-31 explained. The battery unit 400 and the heat exchanger 402 of the Fig. 27 - 31 are similar in design and function to battery unit 300 and heat exchanger 302 of the Fig. 22-26 with the exception of differences arising from the figures and the present description. In particular, as will be explained in detail below, the heat exchanger 402 relies on flexible multiplier plates instead of compressible multiplier protrusions to achieve localized compliance, in order to facilitate substantially parallel compression of the heat exchanger after the insertion of the battery modules 304, in order to maintain good thermal contact between the heat exchanger plates and the battery modules.

[0054] The battery heat exchanger 402 comprises a stack of several (N) substantially identical heat exchanger modules or plates 406(1) to 406(N) (here generally referred to by reference 406) arranged at intervals and aligned substantially parallel to one another in a row or column. The battery unit 400 comprises battery modules 304(1) to 304(N-1) (generally referred to by reference 304) which are interleaved with the heat exchanger plates 406 such that at least one battery module 304 is located between the opposing surfaces of two adjacent heat exchanger plates 406 and is in thermal contact with them.

[0055] The Fig. 27, Fig. 30 and Fig. Figure 31 schematically illustrates four heat exchanger plates 406(1) to 406(4) of the heat exchanger 402. In the illustrated embodiments, the heat exchanger plates 406 and the battery modules 304 have a rectangular plan or profile; however, in other embodiments, they may have other shapes, such as square or circular. As in the battery unit 300, each battery module 304 in the battery unit 400 accommodates at least one battery cell, which may, for example, be a prismatic lithium-ion battery cell (however, other rechargeable battery cells may be used). In the illustrated embodiment, each battery module 304 includes a rectangular, substantially rigid housing or frame that accommodates the one or more battery cells.

[0056] As from the Fig. As can be seen from 29 to 31, the heat exchanger plates 406 each contain a main plate section 434 which includes one or more internal fluid flow paths or passages 408 (in Fig. 29 (shown in dashed lines) between a fluid inlet region or panel 410 and a fluid outlet region or panel 412 is defined. By way of example, each main panel section 434 may contain several substantially parallel, C-shaped internal flow passages 408; however, many different configurations of fluid flow paths are possible, including, for example, a single tortuous flow path through the main panel section 434 between the inlet panel 410 and the outlet panel 412. As is best determined from the Fig. 29 and Fig. As can be seen in Figure 30, the inlet panel 410 defines an inner inlet fluid passage 430, which is in fluid communication with the inner main panel passage 408, and the outlet panel 412 defines an inner outlet fluid passage 432, which is also in fluid communication with the inner main panel passage 408. The inlet panel 410 contains a pair of aligned inlet openings 428I in fluid communication with the inlet fluid passage 430, and the outlet panel similarly contains a pair of aligned outlet openings 428O in fluid communication with the outlet fluid passage 432. In the illustrated embodiments, the inlet and outlet panels 410, 412 are generally rectangular in shape, but they may have different shapes in different embodiments.

[0057] As from the Fig. 27, Fig. 28 and Fig. As can be seen in Figure 29, the inlet panel 410 extends substantially parallel to and at a distance from one end of the main panel section 434, but is attached to the main panel section by a connecting area 440 such that a gap 436 partially separates the inlet panel 410 from the main panel section 434. The connecting area 440 defines an internal fluid passage between the inlet panel passage 430 and the internal main panel passage 408. Similarly, the outlet panel 412 extends substantially parallel to and at a distance from the same end of the main panel section 434, but is attached to the main panel section 434 by a connecting area 442 such that a gap 438 partially separates the outlet panel 412 from the main panel section 434. The gap 438 also extends to separate the inlet panel 410 from the outlet panel 412.The connection area 442 defines an internal fluid passage between the internal main plate passage 408 and the outlet plate passage 412.

[0058] In exemplary embodiments, the connecting areas 440 and 442, although the heat exchanger plate 406 has a generally rigid structure, allow the inlet plate 410 and the outlet plate 412, respectively, to be bent independently of each other relative to the main plate section 434.

[0059] In one embodiment, the fluid inlet plates 410 of all plates 406 are connected in a stack, with the openings 428I being axially aligned to form a common fluid inlet multiplier 414, and the fluid outlet plates 412 are all connected in a stack, with the outlet openings 428O being axially aligned to form a common fluid outlet multiplier 416. During operation, a heat exchange fluid is distributed to each of the heat exchanger plates 406 via the inlet multiplier 414 and collected by the heat exchanger plates 406 via the outlet multiplier 416.In some embodiments, the fluid passing through the inner flow passages 408 is used to cool the heat exchanger plates 406 and the battery modules 304 arranged between them, although in some embodiments the fluid passing through the inner flow passages 408 is used to heat the heat exchanger plates 406 and the battery modules 304 during at least some sections of the battery operation.

[0060] In one embodiment, each heat exchanger plate 406 is formed from a pair of mutually adapted, substantially identical first and second plate parts 418, 420, as best seen from the Fig. 30 and Fig. As can be seen in Figure 31, the first and second plate parts are mirror images of each other. In the illustrated embodiment, the first plate part 418 and the second plate part 420 are each substantially flat parts with externally facing grooves 422 that interact to define internal fluid flow passages 408. The plate parts 418 and 420 each contain an outwardly extending bubble or protrusion 424 on the portion thereof that forms the inlet plate 410, and an outwardly extending bubble or protrusion 426 on the portion thereof that forms the outlet plate 412, wherein the inlet plate protrusion 424 defines an inlet opening 428I and the outlet plate protrusion 426 defines an outlet opening 428O.The inlet plate protrusions 424 of the first and second plate sections 418, 420 of each heat exchanger plate 406 are aligned, and the inlet plate protrusions 424 of all plates 406 are aligned in fluid connection with each other to form the inlet fluid multiplier 414 of the heat exchanger 402. Similarly, the outlet plate protrusions 426 of the first and second plate sections 418, 420 of each heat exchanger plate 406 are aligned with each other, and the outlet plate protrusions 426 of all plates 406 are aligned in fluid connection with each other to form the outlet fluid multiplier 416 for the heat exchanger 402.

[0061] In exemplary embodiments, the first and second plate parts 418, 420 are formed from a brazed aluminum alloy or stainless steel or another sheet material, however, plastic or other synthetic materials may be used in some exemplary embodiments.

[0062] In some embodiments, the heat exchanger 402 is pre-assembled as a unit, as shown in Fig. 27, and are hard-soldered together. Subsequently, the battery modules 304 are inserted between the heat exchanger plates 406 to form a complete battery unit 402. In the illustrated embodiment, both the inlet and outlet multipliers 414, 416 are located on the same side of the heat exchanger 402 to facilitate the lateral insertion of the battery modules 304 from the opposite side of the heat exchanger 402.

[0063] As mentioned above, the presence of columns 436 and 438 between the inlet and outlet panels 410 and 412, respectively, allows the panels 410 and 412 of each heat exchanger plate 406 to flex relative to the main battery plate section 43, and vice versa. After the heat exchanger 402 is pre-assembled (before the battery modules are inserted), the inlet panels 410 are rigidly connected in a stack, with the protrusions 424 aligned to form the inlet multiplier 414, and the outlet panels 412 are rigidly connected in a stack, with the protrusions 426 aligned to form the outlet multiplier 416.The flexible connection between each of the plates 410, 412 and their respective main heat exchanger section 434 allows the main heat exchanger sections 434 to have a pre-compression gap that facilitates the insertion of the battery modules 304, as well as a post-compression gap that provides good thermal contact between the plates and the battery modules 304. For example, as in . Fig. As shown in Figure 31, the heat exchanger 402 has a post-compression intermediate plate separation H. In some embodiments, during the insertion of the battery modules 304, the main plate sections 434 are separated from each other by a distance greater than H, after which the plate sections 434 are pressed together in a substantially parallel manner to the separation distance H in order to achieve thermal contact between the battery modules 304 and the heat exchanger plates 406. Such a configuration can facilitate the insertion of the battery modules 304 during assembly in some applications, while maintaining close thermal contact between the heat exchanger plates 406 and the battery modules 304 after assembly.In exemplary embodiments, the post-compression of the heat exchanger is pre-stressed such that it has an interplate separation H or less than H, so that the battery modules 304 are effectively clamped between pairs of opposing heat exchanger plates 406.

[0064] Accordingly, the heat exchanger 402 uses local compliance in the area of ​​the heat exchanger multipliers to facilitate thermal contact with inserted battery modules 304.

[0065] In some embodiments, tubular intermediate connectors can be used (examples of which are described in detail below in connection with the Fig. 32A, Fig. 32B), which are other than or in addition to the elevations 424, 426, are used to connect the inlet panel and outlet panel sections 410, 412.

[0066] As in the exemplary embodiment of the Fig. 27 and Fig. As shown in Figure 29 of the heat exchanger 400, the flexible panels 410 and 412 are located at the same end of the heat exchanger 400, with the connecting area 440 being located near a center point at the common end and the connecting area 442 being located near a side edge. The multiplier 416 connecting the panels 412 is spaced away from the connecting area 442 and is located near the center point at the end of the heat exchanger 400, and the multiplier 414 connecting the panels 410 is spaced away from the connecting area 440 and is located near the opposite side edge (e.g., the side opposite the connecting area 442).Such a configuration, in which one of the inlet / outlet ports 428I / 428O (and the resulting multiplier) is located near a midpoint at one end of the heat exchanger 402, and the other of the inlet / outlet ports 428I / 428O (and the resulting multiplier) is located at the corner near the same end of the heat exchanger 402, can facilitate parallel compression of the heat exchanger plates 406 in some applications to improve thermal contact after assembly between the heat exchanger plates and the battery modules. However, in some embodiments, Tables 410 and 412 may have different relative locations, and in this respect, the following illustrates... Fig. 29A, Fig. 29B and Fig. 29C shows various possible locations of inlet and outlet panels 410, 412 relative to the main heat exchanger plate sections 434 in heat exchanger embodiments 402-1, 402-2 and 402-3 respectively. The heat exchangers 402-1, 402-2 and 402-3 are essentially identical in design and operation to the heat exchanger 402, the only significant difference being the location of the flexible panels relative to the main heat exchanger section in the heat exchanger plates.

[0067] In the case of the heat exchanger 302 with flexible protrusions according to the Fig. 22 - 26 In at least some embodiments, a multiplier intermediate connector is used between adjacent heat exchanger plates 306. In this respect, the Fig. 32A and Fig. 32B each enlarged partial section views (from a similar perspective to Fig. 23), which illustrate further embodiments of a heat exchanger containing multiplier connectors between compliant raised areas of adjacent heat exchanger plates 306. The heat exchangers of Fig. 32A and Fig. 32B are essentially identical to the heat exchanger 302 of the Fig. 22-26 with the exception of the differences evident from the figures and the present description. As in Fig. As shown in Figure 32A, instead of direct contact between the protrusions 326, adjacent heat exchanger plates 306 (shown as 306(2) and 306(3)) are in Fig. 32A) the opposing projections 326 of adjacent plates 306(2) and 306(3) are arranged at a mutual distance and connected to each other by a cylindrical intermediate connector 340, which forms part of the multiplier 316. In this embodiment of Fig. 32A is the annular wall section 334 of the projection 326 of each opposing plate part 318 and 320 of adjacent heat exchanger plates 306(2), 306(3) received and connected inside within an inner surface of the cylindrical connector 340. The inlet projections 324 are similarly connected by cylindrical intermediate connectors 340. In the exemplary embodiment of the Fig. 32A the elevations 324 and 326 are flexibly deformable, as above with reference to the embodiment of the Fig. 22-26 describes how to enable nesting and thermal contact after assembly with battery modules 304. The embodiment according to Fig. 32B is similar to that of the Fig. 32A, except that the cylindrical connector 340 is inserted into the opposite annular walls 334 of adjacent protrusions 326 (instead of above them).

[0068] In exemplary embodiments, the annular walls 334 and the cylindrical connector 340 are joined by brazing and may incorporate a mechanical interlocking, such as a mechanical connection by hammering or riveting, to facilitate assembly before brazing and to strengthen the connection after brazing. In some exemplary embodiments, an intermediate connector 340 facilitates separate pre-assembly and testing of each of the heat exchanger plates 306, followed by pre-assembly of the heat exchanger as a complete unit, which is then ready for final assembly by nesting battery modules 304 within the heat exchanger structure. The intermediate connector 340 can also be used with heat exchangers with flexible panels 402, 402-1, 402-2, and 402-3. Fig. 27 - 31 can be used.

[0069] The Fig. Figures 33-35 illustrate another flexible heat exchanger 302' for use in a battery unit 300 according to a different embodiment. The heat exchanger 302' is similar to the heat exchanger 302 of the Fig. 22 - 26 and the heat exchangers of the Fig. 32A and Fig. 32B is similar in design and function, with the exception of differences that are apparent from the figures and the present description. Similar to the heat exchangers of the Fig. 32A and Fig. 32B uses the heat exchanger 302' of the Fig. 33 - 35 a multiplier intermediate connector 350 for connecting adjacent heat exchanger plates 306 to each other. However, the heat exchanger 302' differs from the heat exchanger 302 of the Fig. 22 - 26 and the heat exchangers of the Fig. 32A and Fig. 32B by achieving the flexibility of the intermediate heat exchanger plate by providing a two-piece compressible multiplier intermediate connector 350 instead of providing flexible protrusions on the plate parts 320, 318. In this respect, as described in Fig. As shown in Figure 33, in at least some embodiments, the plate parts 318 and 320 of the heat exchanger 302' have non-recessed raised areas around the flow openings 328 (or flow openings 326). Although the figures illustrate a multiplier connector 350 used for the outlet multiplier 316, the inlet multiplier 314 of the heat exchanger 302' is designed in a similar manner.

[0070] An example of a two-piece compressible multiplier intermediate connector 350 is now given with reference to the Fig. Figures 33-35 describe. Terms used here that denote an absolute orientation, such as top and bottom, right and left, are used for descriptive purposes only with reference to the orientation of the figures and not to restrict the configurations described here to an absolute physical orientation. In one embodiment, each multiplier connector 350 defines an internal heat exchanger fluid flow passage 364 for conveying a heat exchanger fluid to or from the heat exchanger plates 306 and includes a first and a second elastic, compressible multiplier attachment 352 and 354. As shown in the Fig. 33 and Fig. As shown in Figure 35, in one embodiment the first fastening 352 comprises an axially extending lower or first annular wall 357, which has a lower end connected to the outlet opening 328 of the upper plate portion 320 of the heat exchanger plate 306(3). The first fastening 352 also comprises an axially extending upper or second annular wall 360, which is adapted to the lower end of the second fastening 354 at a connection 356. The second annular wall 360 has a larger diameter than the first annular wall 357, and the lower end of the second annular wall 360 and the upper end of the first annular wall 357 are connected by a one-piece, generally radially extending annular shoulder 358.

[0071] Similarly, the second attachment 354 includes an axially extending upper or first annular wall 357, which has an upper end connected to the outlet opening 328 of the lower plate portion 318 of the heat exchanger plate 306(2). The second attachment 354 also includes an axially extending lower or second annular wall 360, which is adapted to the upper end of the first attachment 352 at a connection 356. The second annular wall 360 has a larger diameter than the first annular wall 357, and the lower end of the second annular wall 360 and the upper end of the first annular wall 357 are connected by a one-piece, generally radially extending annular shoulder 358.

[0072] In one embodiment, the first and second fastenings 352, 354 are each formed from a single piece of metal material (e.g., aluminum, aluminum alloy, or stainless steel) that is deep-drawn to obtain the shape shown in the figures. In another embodiment, the metal in the shoulders 358 of the first and second fastenings 352, 354 is thinner than the first annular wall 357, thereby giving each of the first and second fastenings 352, 354 a degree of elastic compressibility or compressibility, as shown by the dashed lines 362 and 363 in the figures. Fig. 33 and Fig. Figure 34 illustrates where the dashed lines 362 represent a position of the shoulders 358 after compression and the lines 363 represent a position of the heat exchanger plates 306(2) and 306(3) after compression.

[0073] In one embodiment, each heat exchanger plate 306 is pre-assembled with a pair of first fixings 352 connected to its upper plate portion 320 (one at the outlet opening 328 and one at the inlet opening 326) and a pair of second fixings 354 connected to its lower plate portion 318 (one at the outlet opening 328 and one at the inlet opening 326). Each pre-assembled heat exchanger plate 306 is brazed, and the brazed plate 306 is then inspected for leaks if desired. The heat exchanger plates 306(1) - 306(N) are then stacked to form a complete pre-assembled heat exchanger 302', and the connections 356 between pairs of fixings 352, 354 are brazed. The pre-assembled heat exchanger 302' has an intermediate plate separation distance H1, as shown in Fig. Figure 33 shows how battery modules 304 (which have a height of less than H1) can be nested between the heat exchanger plates 306. After the battery modules 304 are inserted, the heat exchanger 302' is compressed to a height of H2, as shown in Figure 33. Fig. 33 is shown, such that the battery modules 304 are in thermal contact on opposite sides with the heat exchanger plates 306, between which they are each clamped.

[0074] As above with reference to Fig. As explained in section 26, in at least some embodiments the first and second fittings 352, 354 are designed such that they have a snap-through action such that, through an initial deflection range, the fittings 352, 354 are pre-tensioned to the position indicated by solid lines in the Fig. 33 and Fig. Figure 34 shows the position (corresponding to the intermediate plate separation H1), but after a threshold deflection level, the fittings 352, 354 are then biased to the position indicated by dashed lines 362 (corresponding to the intermediate plate separation H2). In some examples, after the threshold deflection is reached, the fittings 352, 354 bias opposing plates 306 into an intermediate plate separation that is smaller than the actual separation distance H2 after assembly, such that the plates 306 effectively clamp the opposing surfaces of the battery module 304 to maintain thermal contact with the battery module over a range of normal operating temperatures of the battery unit 300.

[0075] Fig. Figure 34 illustrates in (B) an example of a possible mechanical connection that can be applied between the first and second fittings 352, 354 at the connection 356, and in (A) possible mechanical connections between the first and second fittings 352, 354 and the respective plates 306. As shown in one example in (B), the lower end of the second fitting 354 is received within the upper end of the first fitting 352, forming an overlap connection. As shown in (A), in some examples an axial flange 364 may be provided around the opening 328 to obtain an overlap connection between the plate and the first or second fitting 352, 354. As shown in Fig. As shown in Figure 35, in some embodiments a rib 366 may be formed on the first annular wall 357 of the fittings 352, 354 to be adapted to the plate 306 around the opening 328, and in some examples the end 368 of a fitting 352, 354 which is inserted into the opening may be widened or hammered or riveted to provide a mechanical connection with the plate before brazing.

[0076] Fig. 36A, Fig. 36B and Fig. Figure 36C shows views of a further embodiment of a fitting consisting of a two-piece flexible multiplier connector, which is used for the heat exchanger according to Fig. 33 can be applied, whereby Fig. 36A is a top view, Fig. 36B a sectional view along line AA in Fig. 36A is, and Fig. Figure 36C is a perspective view. The fitting 370 is essentially identical to the first and second fittings 352, 354, except that the radially extending shoulder 358 of the fitting 370 has an arcuate profile, which provides a weakened area at the transition between the annular walls of the fitting 370, which in some embodiments reduces the compressive force required to move the fitting 370 into its compressed or crushed position.

[0077] Fig. Figure 37 is a sectional view of yet another embodiment of a two-piece flexible multiplier connector 380, which is used in the heat exchanger according to Fig. 33 can be applied. The multiplier connector 380 contains two fittings 382 and 384 and is similar to the connector 350 except that the fittings 382 and 384 are each reversed in such a way that the area of ​​the larger diameter of each fitting is connected to a respective plate 306, and the areas of the smaller diameter of the fittings are connected to each other, thereby giving the connector 380 an hourglass-type shape, in contrast to the connector 350 with a bulging center.

[0078] Although the heat exchanger multipliers 314, 316, 414, 416 have been described above as either specific inlet or outlet multipliers with parallel heat exchanger fluid flow taking place in the same direction through all heat exchanger plates 306, 406, it should be noted that a flow circuit can be used to guide the heat exchanger fluid through the multipliers 314, 316, 414, 416 in various different path configurations by including flow barriers along the respective lengths of one or both of the multipliers.

[0079] Accordingly, in the exemplary embodiments of the Fig. 22-37 the battery units are formed from battery modules nested with heat exchanger plates. In at least some examples, the battery modules are inserted into a pre-assembled heat exchanger, the distance between the heat exchanger plates being dimensioned to accommodate battery modules with acceptable tolerances. After the battery modules are inserted, a compression process or step in the heat exchanger ensures good contact between the heat exchanger plates and the battery modules. In at least some embodiments, the compressible multiplier configuration of the embodiments of Fig. 22 - 26 and 32A - 37 and the flexible inlet / outlet plate configuration of the Fig. 27 - 31 a flexibility to absorb the compression forces in an essentially parallel movement of the plate pairs with fairly limited angular movement of the plates in order to reduce the risk of buckling.

[0080] A common feature of the exemplary embodiments of the Fig. 1-37 is the provision of good thermal contact between battery modules and the heat exchanger modules after assembly, wherein the thermal contact is facilitated by elastic compliance of areas of the respective heat exchanger structures. In at least some embodiments, compliant areas of the heat exchangers of the Fig. 1 - 37 are at least temporarily displaced when areas of the heat exchangers are positioned between battery modules.

[0081] The various embodiments described above are merely examples and are in no way intended to limit the scope of this disclosure. Modifications to the innovations described herein are obvious to the person skilled in the art, and such modifications are within the intended scope of this disclosure. In particular, features from one or more of the embodiments described above can be selected to create alternative embodiments consisting of a subcombination of features not expressly described above. Additionally, features from one or more of the embodiments described above can be selected and combined to create alternative embodiments consisting of a combination of features not expressly described above.Features suitable for such combinations and subcombinations are obvious to a person skilled in the art when considering the present disclosure as a whole. The subject matter described herein and in the reproduced claims is intended to cover and encompass all suitable modifications of the technology.

Claims

[1] Method for assembling a battery unit (100, 300, 400) comprising: Providing a substantially rigid heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) which provides an internal fluid passage (118, 126, 218, 226, 308, 408) for a heat exchanger fluid and has at least one flexible region (230, 324, 326, 352, 354, 370, 380, 424, 426); and Positioning at least a part of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) between two battery modules (102(1) - 102(6), 304(1)-304(2)), each of the battery modules (102(1) - 102(6), 304(1)-304(2)) comprising at least one battery cell (106) contained in a rigid container (104), and wherein the positioning of at least a part of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) involves at least a temporary deformation or displacement of the at least one compliant region (230, 324, 326, 352, 354, 370, 380, 424, 426) of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)). [2] Method according to claim 1, wherein the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) defines several elastic, independently compressible areas and the battery modules (102(1) - 102(6), 304(1)-304(2)) each contain several battery cell containers (104) that contact the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)), and wherein the positioning of at least a part of the heat exchanger between two battery modules (102(1) - 102(6), 304(1)-304(2)) comprises positioning the independently compressible areas in alignment with the respective battery cell containers (104). [3] The method of claim 1, wherein: The provision of a heat exchanger (302, 302', 402(1) - 402(3)) comprises: providing several substantially planar heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) arranged at a distance from one another, each defining an internal fluid passage (308, 408), each of the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) having a first projection (324, 424) projecting from a first side and a second projection (326, 426) projecting in the opposite direction from a second side, the first projecting projection (324, 424) and the second projecting projection (326, 426) being substantially aligned with each other and each having a flow opening in connection with the internal fluid passage (308, 408) define, and at least one of the first and second elevations (324, 326, 424, 426) is so yielding that it can be compressed from a first projecting distance to a second projecting distance, the first elevation (324, 424) of at least some of the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) is connected to the second elevation (326, 426) of an adjacent heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)); and wherein the positioning of at least a part of the heat exchanger (302, 302', 402(1) - 402(3)) between two battery modules comprises: Inserting battery modules between pairs of heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) in such a way that the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) and battery modules are interlocked; and Compressing the yielding elevations (324, 326, 424, 426) from the first projecting distance to the second projecting distance. [4] Method according to claim 3, wherein at least some of the flexible projections (324, 326, 424, 426) are pre-tensioned towards the first projecting distance until compressed to a threshold distance, wherein the at least some of the flexible projections (324, 326, 424, 426) are pre-tensioned towards the second projecting distance, wherein the compression of the flexible projections (324, 326, 424, 426) from the first projecting distance to the second projecting distance comprises the compression of the at least some of the flexible projections (324, 326, 424, 426) beyond the threshold distance in such a way that the at least some of the flexible projections (324, 326, 424, 426) snap towards the second projecting distance. [5] Method according to claim 3 or 4, comprising forming the protrusions (324, 326, 424, 426) by deep drawing a region of the material forming the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)). [6] The method of claim 1, wherein: the provision of a heat exchanger (302, 302', 402(1) - 402(3)): Providing several substantially planar heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)), each defining an internal fluid passage (308, 408), each of the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) having a first opening on one side thereof and a second opening opposite the first opening (326, 426) on a second side, and the first and the second opening (326, 426, 328) being connected to the internal fluid passage (308, 408), for at least some of the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) connecting a first multiplier attachment (352) defining a fluid flow passage, extending from the first side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)), wherein the inner fluid flow passage of the first multiplier attachment (352) is connected via the first opening to the inner fluid flow passage (308, 408) of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)), for at least some of the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) connecting a second multiplier attachment (354) defining a fluid flow passage, extending from the second side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)), wherein the inner fluid flow passage of the second multiplier attachment (354) is connected via the second opening (328) to the inner fluid passage (308, 408) of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)), Connecting the first multiplier attachment (352) of at least some of the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) to the second multiplier attachment (354) of adjacent heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) to form a stack of substantially parallel heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) spaced apart, wherein the first multiplier attachment (352) and the second multiplier attachment (354) each have a first annular wall (357), comprising a second annular wall (360) with a diameter larger than that of the first annular wall (357), and a radial shoulder region (358) connecting the first annular wall (357) and the second annular wall (350), wherein the radial shoulder region (358) is flexible enough to allow an extending end of the multiplier attachment (352, 354) to be partially compressed towards the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)); and in the the positioning of at least part of the heat exchanger (302, 302', 402(1) - 402(3)) between two battery modules (304(1)-304(2)): Inserting battery modules (304(1)-304(2)) between pairs of heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) such that the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) and the battery modules (304(1)-304(2)) are interlocked; and Compressing the multiplier fixings (352, 354) to reduce the distance between the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)). [7] Method according to claim 6, wherein at least some of the multiplier fastenings (352, 354) are designed to snap into a compressed dimension after being compressed by a threshold amount. [8] Method according to claim 6 or 7, comprising forming the multiplier attachments (352, 354) by deep drawing a metal material. [9] The method of claim 1, wherein: the provision of a heat exchanger (402(1) - 402(3)): Providing several essentially rigid and planar heat exchanger plates (406(1) - 406(4)), each comprising a main plate section (434) defining an internal fluid passage (408), and an inlet plate (410) and an outlet plate (412) connected to the main plate section (434) and defining an inlet fluid passage and an outlet fluid passage, respectively, communicating with the internal fluid passage (408), wherein each of the plates (410, 412) is flexibly connected to the main plate section (434) such that the main plate section (434) can be displaced relative to the plates (410, 412), and rigidly connecting the inlet and outlet plates (410, 412) of at least some of the heat exchanger plates (406(1)-406(4)) with the inlet and outlet plates (410, 412) of adjacent heat exchanger plates (406(1)-406(4)) to form a stack of substantially parallel heat exchanger plates (406(1)-406(4)) spaced apart from each other; and in the the positioning of at least part of the heat exchangers (402(1) - 402(3)) between two battery modules: Inserting battery modules between pairs of heat exchanger plates (406(1)-406(4)) such that the heat exchanger plates (406(1)-406(4)) and battery modules are nested; and pressing the main plate sections (434) together. [10] Battery unit (100, 300, 400) comprising: a heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) and two battery modules (102(1) - 102(6), 304(1)-304(2)), each of the battery modules (102(1) - 102(6), 304(1)-304(2)) comprising at least one battery cell (106) contained within a rigid container (104), the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) defining an internal fluid passage (118, 126, 218, 226, 408) for a heat exchanger fluid and at least one has a compliant area (230, 324, 326, 352, 354, 370, 380, 424, 426) which is designed to be compressed to facilitate thermal contact between the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) and the two battery modules (102(1) - 102(6), 304(1)-304(2)); characterized by , that at least part of the heat exchanger (110, 210, 302, 302', 402(1) - 402(3)) is positioned between the two battery modules (102(1) - 102(6), 304(1)-304(2)). [11] Heat exchanger for use with at least two battery modules, wherein each of the battery modules (304(1)-304(2)) has at least one battery cell contained within a rigid container, the heat exchanger defines an internal fluid passage (308) for a heat exchanger fluid and has at least one compliant area (324, 326, 352, 354, 370, 380) configured to be compressed to facilitate thermal contact between the heat exchanger (302, 302') and the two battery modules (304(1)-304(2)); wherein the heat exchanger comprises: Several substantially planar heat exchanger plates (306(1)-306(3)) arranged at mutual intervals, each defining an internal fluid passage (308), each of the heat exchanger plates (306(1)-306(3)) having a first projection (324) projecting from a first side and a second projection (326) projecting in an opposite direction from a second side, the first projecting projection (324) and the second projecting projection (326) being substantially aligned with each other and each defining a flow opening in association with the internal fluid passage (308, 408), at least one of the first and the second projection (324, 326) being compliant to be compressible from a first projecting distance to a second projecting distance such that, after battery modules (304(1)-304(2)) are inserted between pairs of the heat exchanger plates (306(1)-306(3)) are introduced in this way,that the heat exchanger plates (306(1)-306(3)) and battery modules (304(1)-304(2)) are nested, the compliant protrusions (324, 326) can be compressed from the first projecting distance to the second projecting distance. [12] Heat exchanger according to claim 11, wherein at least some of the compliant projections (324, 326) are pre-tensioned towards the first projecting distance until they are compressed to a threshold distance, after which the at least some of the compliant projections (324, 326) are pre-tensioned towards the second projecting distance. [13] Heat exchanger according to claim 11 or 12, wherein the protrusions (324, 326) of each heat exchanger plate (306(1)-306(3)) are deep drawn from a region of the material forming the heat exchanger plate (306(1)-306(3)). [14] Heat exchanger for use with at least two battery modules, wherein each of the battery modules (304(1)-304(2)) has at least one battery cell contained within a rigid container, the heat exchanger defines an internal fluid passage (308) for a heat exchanger fluid and has at least one compliant area (324, 326, 352, 354, 370, 380) configured to be compressed to facilitate thermal contact between the heat exchanger (302, 302') and the two battery modules (304(1)-304(2)), wherein the heat exchanger comprises: several substantially planar heat exchanger plates (306(1)-306(3)) each defining an internal fluid passage (308), each of the heat exchanger plates (306(1)-306(3)) having a first opening on a first side thereof and a second opening opposite the first opening on a second side, the first and the second opening being connected to the internal fluid passage (308), at least some of the heat exchanger plates (306(1)-306(3)) have a first multiplier attachment (352) that defines a fluid flow passage and extends from the first side of the heat exchanger plate (306(1)-306(3)), wherein the inner fluid flow passage (308, 408) of the first multiplier attachment (352) communicates with the inner fluid passage (308) of the heat exchanger plate (306(1)-306(3)) via the first opening, at least some of the heat exchanger plates (306(1)-306(3)) have a second multiplier attachment (354) that defines a fluid flow passage and extends from the second side of the heat exchanger plate (306(1)-306(3)), wherein the inner fluid flow passage of the second multiplier attachment (354) communicates with the inner fluid passage (308) of the heat exchanger plate (306(1)-306(3)) via the second opening, the first multiplier attachment (352) of at least some of the heat exchanger plates (306(1)-306(3)) are connected to the second multiplier attachment (354) of an adjacent heat exchanger plate (306(1)-306(3)) to form a stack of substantially parallel heat exchanger plates (306(1)-306(3)) arranged at a distance from each other, wherein the first multiplier attachment (352) and the second multiplier attachment (354) each have a first annular wall (357), comprising a second annular wall (360) with a diameter larger than that of the first annular wall (357), and a radial shoulder region (358) connecting the first annular wall (357) and the second annular wall (360), and the radial shoulder region (358) being compliant to allow an extending end of the multiplier attachment (352, 354) to be partially compressed towards the heat exchanger plate (306(1)-306(3)); and wherein battery modules can be inserted between pairs of heat exchanger plates (306(1)-306(3)) such that the heat exchanger plates (306(1)-306(3)) and battery modules (304(1)-304(2)) are nested and the multiplier fixings (352, 354) are compressed to reduce the distance between the heat exchanger plates (306(1)-306(3)). [15] Heat exchanger according to claim 14, wherein at least some of the multiplier attachments (352, 354) are designed to snap into a compressed dimension after being compressed by a threshold amount. [16] Heat exchanger according to claim 14 or 15, wherein the fastenings (352, 354) are formed by deep drawing a metal material. [17] Heat exchanger for use with at least two battery modules, wherein each of the battery modules has at least one battery cell contained within a rigid container, the heat exchanger defines an internal fluid passage (408) for a heat exchanger fluid and has at least one compliant area configured to be compressed to facilitate thermal contact between the heat exchanger (402) and the two battery modules, wherein the heat exchanger comprises: several essentially rigid, planar heat exchanger plates (402(1) - 402(3)), each comprising a main plate section (434) defining an internal fluid passage (408), and an inlet plate (410) and an outlet plate (412) connected to the main plate section (434) providing an inlet fluid passage and an outlet passage, respectively.Defining an outlet fluid passage that communicates with the internal fluid passage (408), wherein each of the panels (410, 412) is flexibly connected to the main plate section (434) in such a way that the main plate section (434) can be displaced relative to the panels (410, 412), the inlet and outlet panels (410, 412) of at least some of the heat exchanger plates (402(1) - 402(3)) are connected to the inlet and outlet panels (410, 412) of adjacent heat exchanger plates (402(1) - 402(3)) to form a stack of mutually spaced, substantially parallel heat exchanger plates (402(1) - 402(3)), and the main plate sections (434) are compressible towards each other to engage with battery modules inserted between them. (406(1) - 406(4)) to occur. [18] Heat exchanger for use with at least two battery modules, wherein each of the battery modules (304(1)-304(2), 406(1) - 406(4)) has at least one battery cell contained within a rigid container, the heat exchanger defines an internal fluid passage (308, 408) for a heat exchanger fluid and has at least one compliant area (324, 326, 352, 354, 370, 380, 424, 426) configured to be compressed to facilitate thermal contact between the heat exchanger (302, 302', 402(1)-402(3)) and the two battery modules (304(1)-304(2), 406(1) - 406(4));wherein the heat exchanger (302, 402(1)-402(3)) defines several elastic, independently compressible areas (324, 326, 424, 426), and the battery modules (304(1)-304(2), 406(1)-406(4)) each contain several battery cell containers that contact the heat exchanger (302, 402(1)-402(3)), and wherein the independently compressible areas (324, 326, 424, 426) are positioned in alignment with respective battery cell containers. [19] Heat exchanger (302, 302', 402(1) - 402(3)) for exchanging thermal energy with battery modules (304(1)-304(2)), comprising: several heat exchanger plates, each defining an internal fluid passage for a heat exchanger fluid and having compliant protrusions (324, 326, 424, 426) formed integrally with them, the heat exchanger plates being arranged in a stack with adjacent heat exchanger plates that are spaced apart from each other and are connected to each other by the compliant protrusions (324, 326, 424, 426) to allow compression of the adjacent heat exchanger plates following the insertion of battery modules between the heat exchanger plates. [20] Heat exchanger (302, 302', 402(1) - 402(3)) according to claim 19, wherein each heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) has a pair of flexible projections (324, 424) extending from the first side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) and a pair of flexible projections (326, 426) extending from a second side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)), wherein the projections (324, 326, 424, 426) each have a respective flow opening in conjunction with the inner define flow passage (308, 408), wherein for intermediate plates in the stack the pair of protrusions (324, 326, 424, 426) extending from the first side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) to the pair of protrusions (324, 326, 424, 426) extending from a second side of an adjacent heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)),is attached and the connected protrusions (324, 326, 424, 426) of the stack form inlet and outlet multipliers (314, 316, 414, 416) for the heat exchanger fluid. [21] Heat exchanger according to claim 20, wherein the protrusions (324, 326, 424, 426) which are connected to each other are connected by an intermediate connector (340, 350). [22] Heat exchanger according to claim 20, wherein the protrusions (324, 326, 424, 426) which are connected to each other are directly brazed together. [23] Heat exchanger (302, 302', 402(1) - 402(3)) according to any one of claims 20 to 22, wherein the heat exchanger plates (306(1) - 306(3), 406(1) - 406(4)) are substantially rectangular, flat plates in which the pairs of protrusions (324, 326, 424, 426) are located on one side, thereby enabling the heat exchanger modules to be inserted into the heat exchanger (302, 302', 402(1) - 402(3)) from an opposite side thereof. [24] Heat exchanger (302, 302') according to any one of claims 19 to 23, wherein each projection has a first annular wall (330) which is connected to and extends away from a flat surface of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) and terminates at an inwardly extending annular shoulder (332) which terminates at a second annular wall (334) which extends away from the first annular wall (330), wherein the shoulder (332) is movable to facilitate compression of the projection (324, 326). [25] Heat exchanger (302, 302') according to claim 24, in which each projection (324, 326) is pre-tensioned to a first position until it is offset to a threshold distance, after which the projection (324, 326) is pre-tensioned to a compressed position. [26] Heat exchanger (302, 302') according to any one of claims 19 to 23, wherein each projection has a first annular wall (330) which is connected to and extends away from a flat surface of the heat exchanger plate (302, 302', 402(1) - 402(3)), wherein the first annular wall (330) includes an outwardly extending bellows (325) such that the first annular wall (330) can be compressed. [27] Heat exchanger (302, 302', 402(1) - 402(3)) according to any one of claims 19 to 26, wherein the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) comprises a first plate and a second plate which are attached to one another and define the fluid flow passage (308, 408) between them, wherein the pair of protrusions (324, 326, 424, 426) extending from the first side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) is formed from the first plate, and the pair of protrusions (324, 326, 424, 426) extending from the second side of the heat exchanger plate (306(1) - 306(3), 406(1) - 406(4)) extends away, is formed from the second plate. [28] Heat exchanger (302) for exchanging thermal energy with battery modules (304(1)-304(2)), which comprises: Several heat exchanger plates (306(1) - 306(3)), each defining an internal fluid flow passage for a heat exchanger fluid and arranged in a stack in which adjacent heat exchanger plates (306(1) - 306(3)) are spaced apart, the adjacent heat exchanger plates (306(1) - 306(3)) are flexibly connected to each other by intermediate connectors (350, 370, 380) that allow heat exchanger fluid to flow between the plates (306(1) - 306(3)), and which are flexible to allow the adjacent heat exchanger plates (306(1) - 306(3)) to be compressed together after the introduction of battery modules (304(1)-304(2)) between the heat exchanger plates (306(1) - 306(3)), wherein the intermediate connectors (350, 370, 380) are designed to snap into a compressed state after a compression threshold is reached. [29] Heat exchanger according to claim 28, wherein at least some of the heat exchanger plates (306(1) - 306(3)) have a pair of intermediate connectors (350, 370, 380) extending from a first side of the heat exchanger plate (306(1) - 306(3)) and a pair of intermediate connectors (350, 370, 380) extending from a second side of the heat exchanger plate (306(1) - 306(3)), wherein the intermediate connectors (350, 370, 380) each define a respective flow channel in conjunction with the inner flow passage, for each of the intermediate plates (306(1) - 306(3)) in the stack the pair of intermediate connectors (350, 370, 380) extending from the first side of the heat exchanger plates (306(1) - 306(3)) extends to the pair of intermediate connectors (350, 370, 380) extending from a second side of an adjacent heat exchanger plate (306(1) - 306(3)), and the connected intermediate connectors (350, 370,380) of the stack form inlet and outlet multipliers (314, 316) for the heat exchanger fluid. [30] Heat exchanger according to claim 29, wherein the intermediate connectors (350, 370) which are connected to each other are directly brazed together, and the intermediate connectors (350, 370) are brazed to the heat exchanger plates (306(1) - 306(3)). [31] Heat exchanger according to one of claims 28 and 29, wherein the heat exchanger plates (306(1) - 306(3)) are substantially rectangular, flat plates, wherein the pairs of intermediate connectors (350, 370, 380) are located on one side of these, thereby enabling the heat exchanger modules to be inserted into the heat exchanger (302) from an opposite side thereof. [32] Heat exchanger according to any one of claims 28 to 30, wherein the intermediate connectors (350, 370, 380) each comprise a first annular wall (357), a second annular wall (360) having a diameter larger than that of the first annular wall (357), and a radial shoulder region (358) connecting the first annular wall (357) and the second annular wall (360), wherein the radial shoulder region (358) is flexible in such a way as to allow an extending end of the intermediate connector (350, 370, 380) to be partially compressible towards the heat exchanger plate (306(1) - 306(3)). [33] Heat exchanger according to claim 32, wherein the radial shoulder area (358) is curved to facilitate compression of the intermediate connector (370). [34] Heat exchanger according to claim 32 or 33, wherein the first annular wall (357) of each intermediate connector (350, 370) is connected to a respective heat exchanger plate (306(1) - 306(3)) and the second annular wall (360) is connected to the second annular wall (360) of an intermediate connector (350, 370) of an adjacent heat exchanger plate (306(1) - 306(3)). [35] Heat exchanger according to claim 32 or 33, wherein the second annular wall of each intermediate connector (380) is connected to a respective heat exchanger plate (306(1) - 306(3)) and the first annular wall is connected to the first annular wall (357) of an intermediate connector (380) of an adjacent heat exchanger plate (306(1) - 306(3)). [36] Heat exchanger (402(1) - 402(3)) for exchanging thermal energy with battery modules, comprising: several heat exchanger plates (406(1) - 406(4)), each defining an internal fluid flow passage (408) for a heat exchanger fluid and arranged in a stack in which adjacent heat exchanger plates (406(1) - 406(4)) are spaced apart from each other, wherein the adjacent heat exchanger plates (406(1) - 406(4)) each have a main plate section (434) and an inlet plate (410) and an outlet plate (412) connected to the main plate section (434) and providing an inlet fluid passage (430) and an outlet plate (412), respectively.Defining an outlet fluid passage (432) that communicates with the internal fluid passage (408), each of the plates (406(1) - 406(4)) is flexibly connected to the main plate section (434) in such a way that the main plate section (434) can be displaced relative to the plates (410, 412), the inlet and outlet plates (410, 412) of at least some of the heat exchanger plates (406(1) - 406(4)) are connected to the inlet and outlet plates (410, 412) of adjacent heat exchanger plates (406(1) - 406(4)) to form a stack of substantially parallel heat exchanger plates (406(1) - 406(4)) arranged at a distance from each other, the main plate sections (434) being displaced relative to their respective inlet and outlet plates. (410, 412) are movable at least before the introduction of battery modules between the heat exchanger plates (406(1) - 406(4)). [37] Heat exchanger according to claim 36, wherein the main plate sections (434) are compressible to provide thermal contact with battery modules inserted between the heat exchanger plates (406(1) - 406(4)). [38] Heat exchanger according to claim 36 or 37, wherein the inlet and outlet panels (410, 412) are located on a common side of the heat exchanger stack to facilitate the insertion of battery modules into the stack from an opposite side. [39] Heat exchanger according to claim 36 or 37, wherein the inlet and outlet panels (410, 412) are located on opposite sides of the heat exchanger stack to facilitate the insertion of battery modules into the stack from an opposite side. [40] Heat exchanger according to any one of claims 28 to 39, wherein each heat exchanger plate (406(1) - 406(4)) has a first plate and a second plate which are attached to each other and define the fluid flow passage (408) between them. [41] Heat exchanger according to any one of claims 19 to 40, wherein the heat exchanger plates (406(1) - 406(4)) are made of metal material and are brazed together. [42] Battery unit (300, 400) comprising several battery modules nested with the heat exchanger (302, 302', 402(1) - 402(3)) according to any one of claims 11 to 41.

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