Conformal fluid-cooled heat exchanger for batteries

Abstract

Battery unit (100), which includes: a first battery module (102(1)); a second battery module ( 102(2)), wherein the first battery module (102(1)) and the second battery module (102(1)) are spaced apart from each other; and a heat exchanger (110, 210) arranged between the first battery module (102(1)) and the second battery module (102(2)), with a first side in contact with the first battery module (102(1)) and a second side in contact with the second battery module (102(2)), wherein the heat exchanger (110, 210) defines at least one internal fluid flow passage (118) for transferring a heat exchanger fluid, the first and second sides of the heat exchanger (110) being elastically compressible to adapt to changes in the distance between the first and second battery modules (102(1), 102(2)); wherein the heat exchanger ( 110, 210) has several independently compressible areas that are positioned between and in engagement with the first battery module (102(1)) and the second battery module (102(2)); characterized by the fact that the first battery module (102(1)) has several battery cell containers (104), each of which accommodates at least one battery cell (106); the second battery module (102(2)) has several battery cell containers (104), each of which accommodates at least one battery cell (106), wherein the battery cell containers (104) of the first battery module (102(1)) are located at a distance from and opposite respective battery cell containers (104) of the second battery module (102(2)) and each of the independently compressible areas is positioned between and in engagement with a respective battery cell container (104) of the first battery module (102(1)) and a respective battery cell container (104) of the second battery module (102(2)), wherein each of the individually compressible areas is adapted to the distance between the battery cell containers (104) between which it is positioned.

Description

Cross-reference to related registration

[0001] This application claims priority over 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. background

[0002] This disclosure relates to heat exchangers used for dissipating heat in rechargeable batteries and other electricity-generating cells.

[0003] 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). These batteries can generate large amounts of heat that must be dissipated.

[0004] Document JP 2000-048 867 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 / 071 616 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 / 0285051A1 deals with barriers with front surfaces designed to contact battery units and curved to bend elastically. Summary

[0005] The present invention is defined in the independent claims. Individual embodiments are specified in the dependent claims. 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 an expanded representation 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 plate 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. Description of the exemplary implementations

[0006] Specific implementations of the technology will now be discussed. Each example is provided solely for illustrative purposes and not as a limitation of the technology. It is evident to those skilled in the art that various modifications and variations of the present technology are possible. For example, features described as part of one implementation of the technology may be used in another implementation to obtain yet another implementation. Thus, the present technology is intended to cover such modifications and variations as fall within the scope of the technology.

[0007] 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 orientation in this description are given only as an example of an illustrative embodiment.

[0008] In at least some embodiments, the battery cells 106 are lithium-ion battery cells, although 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 of 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 container 104 may not be rigid.

[0009] 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 arranged between them do not need to have perfectly flat surfaces and may still be subject to distortions due to expansion and contraction during heating and cooling.

[0010] Illustrated by example Fig. 2 a contact surface 112 defined by the 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 and module assembly tolerances, the cell containers 104 may not be perfectly identical or perfectly aligned with each other. As a consequence, the heat exchanger contact faces 114 are not aligned with each other, 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. In a non-restrictive example, the tolerance T may be in the range of 0.5 mm to 1 mm for some applications, but in other applications the tolerance may also be outside this range.

[0011] Accordingly, in some applications, a heat exchanger 110 is desirable 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 offer good thermal conductivity. In this respect, exemplary embodiments refer to a heat exchanger structure that is dimensionally flexible 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 when the first and second battery modules expand and expands when the first and second battery modules subsequently contract, such that the heat exchanger structure remains in thermal contact with the battery cell containers 104 over a range of normal battery operating temperatures.

[0012] According to the Fig. 3 and Fig. In one embodiment, the heat exchanger 110 is a multi-path plate-type heat exchanger, which defines an internal helical (serpentine) 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 designated by reference numeral 116(i) and indicated by dashed lines in ). Fig. (Figure 3), 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 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 the outlet fitting 122. The heat exchange fluid passing through the inner flow passage 118 can, for example, be a cooling liquid such as water or another liquid, or a gaseous fluid 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.

[0013] 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 a 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 a respective opposing pair of battery cell containers 104 in the battery unit 100. However, the number of fluid chambers may 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 exposed 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 located 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 referred to by the reference number 124(i)) of the heat exchanger 110. As will be explained in detail later, in 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 in such a way that variations in the inter-cell container on opposing surfaces 112, 113 between the adjacent modules 102(1) and 102(2) can be compensated by the heat exchanger 110.

[0014] According to the in the Fig. In the sectional views of the heat exchanger 110 shown in Figures 5-7, the body of the heat exchanger 110 is formed in one embodiment from six stacked plates, namely a first and a second outer cover plate 128, 130; a first and a second outer core plate 132, 134; and a first and a second inner core plate 136, 138. In one embodiment, the plates are each made of roll-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 made of other elastic metals or materials, including plastics, and by other processes.

[0015] 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, coiled projection 142 formed on it. The coiled projection 142 corresponds to the shape of the inner flow passage 118 and contains parallel inner core plate areas 143(1) - 143(6) (generally designated by the 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.

[0016] 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 coiled part that corresponds 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 the reference numeral 154(i)) connected in series, corresponding to the respective flow chamber regions 124(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 flexibly 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.

[0017] 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 that conforms to the shape of the inner flow passage 118. The cover plate 128 contains parallel first cover plate regions 158(1) - 158(6) (generally designated by reference numeral 158(i)) connected in series, corresponding to the respective flow chamber regions 124(1) - 124(6). Adjacent first cover plate regions 158(i) are connected by substantially U-shaped regions 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). An enlarged inlet orOutlet openings 162, 164 are provided at opposite ends of the coiled cover plate 128.

[0018] 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 and 164. The same reference numerals are used in the figures for similar elements in the cover plates 128 and 130.

[0019] The features of plates 128, 130, 132, 134, 136 and 138 and their assembly 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, inner core plates 136 and 138 are connected to each other with their respective flat plate areas 140 in mutual contact, their respective raised projections 142 extending away from a center line C of the heat exchanger body. For explanatory purposes, the term "inner" used here indicates a direction towards the center line C, while the term "outer" indicates a direction away from the center line C, unless the context suggests otherwise. The raised projections 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 each of the first and second inner core plates 136, 138 is formed by opposing side walls 166 extending from the flat plate area 140 and each terminating at a flat flange 168 defining 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 area 170 curved outwards relative to the center line C, and a second arcuate wall area 172 curved inwards relative to the center line C, thus giving the side wall 166 a profile generally approximating an "S" shape.In some exemplary configurations, such a sidewall profile results in 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 distribute the stress in some embodiments, thus reducing fatigue; however, other sidewall configurations can alternatively be used to reduce fatigue.

[0020] The first outer core plate 132 and the second outer core plate 134 are attached to the first inner core plate 136 and the second core plate 138, respectively, on opposite sides of the centerline C. 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, facing 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 giving the side wall 176 a profile that generally approximates an "S" shape. In one example, the inner flanges 186 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.

[0021] The inner flanges 180 of the first outer core plate 132 are adapted to respective flat areas 168 of the first inner core plate 136 in order to fasten 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 leakage from the inner plate. It can also help to align the plates relative to each other 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 limiting factor 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 restrict deformation in such areas. The second outer core plate 134 is attached to the second inner core plate 138 in a similar manner to how the first outer core plate 132 is attached 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 in the outer core plate.

[0022] 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 deform towards the centerline C under compression and can then spring back to a normal shape when the compression is removed. In some embodiments, the generally S-shaped side wall profile can distribute the stress in such a way as to reduce fatigue; however, other side wall configurations can alternatively be used to reduce fatigue.

[0023] In the illustrated embodiment, the coiled first outer cover plate 128 is attached to an outer surface of the coiled first outer core plate 132 to seal the first outer core plate channel 174. Each of the cover plate sections 158(i) and U-shaped sections includes a flat central section 188 with inwardly facing flanges 190 along its opposite circumferential edges. Peripheral portions of the flat central section 188 are adapted to the flat outer flanges 178 of the first outer core plate 132, the flat outer flanges 178 of the outer core plate being received in the inwardly facing 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 surface of the coiled second outer core plate 134 to seal the second outer core plate channel 174.The inwardly directed flanges 190 can, in some embodiments, aid in the positioning of 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 mounting 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 heat exchanger fluid inlet and fluid outlet on the side of the heat exchanger opposite the side where the inlet and outlet fitting 120, 122 is located. According to the... Fig. In the embodiment described here, each fluid chamber 116(i) of each fluid region 124(i) contains three interconnected flow regions: channel 174, defined by the first cover plate 128 and the first outer core plate 132; channel 174, defined by the second cover plate 130 and the second outer core plate 134; and the central channel 192, defined between the first core plates 136 and 138. As a consequence of the slots 144 and 149, the channels 174 and 192 are fluid-connected along the entire length of the coiled flow passage 118.

[0024] 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 in the second first battery module 102(1) on the opposite side of the heat exchanger. 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, the 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, between which the fluid chamber area 124(i) is located. The pressure of the heat exchanger fluid within the flow chambers 116(i) can, in some embodiments, cause the fluid flow areas 124(i) to become compressible.

[0025] As non-restrictive examples, in some applications the plates used to form heat exchanger 110 may consist of H3534 aluminum brazing sheet and / or 3003 aluminum. Alternative plate configurations can be used to achieve similar results—for example, fewer than six plates can be used to form a heat exchanger with individually compliant flow regions.

[0026] 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 the 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 a substantially planar first and second flexible plate structure 230. In embodiments, the flexible plate structures 230 are each designed to be elastically deformable such that the heat exchanger 210 is dimensionally flexible in 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 fluid flow passage 218 of the heat exchanger with a first end in fluid connection with an inlet fitting 220 and a second end in fluid connection 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 the reference number 216(i) - see ). Fig. 15), wherein each fluid chamber is connected to a subsequent fluid chamber by a respective, 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 from the outlet fitting 222.

[0027] 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).

[0028] 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.

[0029] 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 the first and second core plates 232, 234, which are opposite each other; and the first and second flexible plate structures 233 are each formed from opposing flexible plates 236. In one embodiment, the plates are each formed from roll-formed or stamped aluminum or an aluminum alloy and 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.

[0030] 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 the respective core plates 234 and 232. The core plates 234 and 232 each contain a rectangular, flat plate area 240 with a raised, coiled projection 242 formed therein. The coiled projection 242 is adapted to the shape of the inner flow passage 218 and contains parallel core plate areas 234(1) - 234(6) (generally designated by the reference number 234(i)), which correspond to the respective flow chamber areas 224(1) - 224(6). A difference between the first core plate 232 and the second core plate 234 is that an inlet and outlet opening 246, 248 are formed at opposite ends of the raised projection 242 of the first core plate 232.

[0031] 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. 20 an example of a compliant plate 236. In the illustrated example, the compliant plate 236 is a rectangular plate containing several raised, parallel elongated protrusions 250 separated by slots 252 extending through the plate. Fig. Figure 21 is an enlarged partial sectional view showing two flexible plates 236 fitted opposite each other to form a flexible plate structure 230. As can be seen from 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 adapted to the flanges 258 of the opposite flexible plate 236 to form a flexible plate structure 230. As can be seen from Fig. As can be seen in Figure 21, the opposing protrusions 250 of the adapted flexible plates 236 define inner chambers 260 such that the adapted flexible plates 236 define several parallel, elongated flexible 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 with a non-fluid thermal seal. In another embodiment, the chambers 260 can be vented. In the illustrated embodiment, the flexible plate structure 230 contains twelve elongated flexible regions 262(i), two for each of the six flow chamber regions 224(i) of the core plate structure 228.

[0032] In one embodiment, the compliant areas 262(i) ​​of the compliant plate structure 230 are each individually deformable such that each of the compliant areas 262(i) ​​can be individually compressed under external pressure up to a threshold amount and then spring back to its initial shape after the pressure is removed.

[0033] In some embodiments, the flexible plates 236 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 between which it is sandwiched. In a non-limiting 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.

[0034] In 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 fluid flow passage 218 of the heat exchanger. 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) extends 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 with respect to the physical separation between the two battery cell containers 104, between which the fluid chamber area 124(i) is located.

[0035] Accordingly, in the exemplary embodiments of the Fig.A heat exchanger 110, 210 is 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 the opposite sides of the heat exchanger 110, 210 may not be perfectly flat due to a lack of perfect alignment of the battery cell containers that form the battery modules 102(1) and 102(2). Thus, in at least some embodiments, in order 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 effect such that each adjustable area corresponds to a respective pair of opposite battery cell containers and can bend adaptively under the compression forces exerted on the area.Accordingly, in at least some embodiments, when a battery unit is assembled which includes battery modules 102(1), 102(2) and heat exchangers 110, 210, a compression process or step occurs, during which 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, 210.

[0036] In some embodiments, the previously described configurations of the conformal heat exchanger can be used between fuel cell modules instead of battery cell modules.Accordingly, the heat exchanger structures described here can be used in an energy-generating unit comprising a first module with several energy-generating cells, such as battery cells or fuel cells, and a second module with several energy-generating 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 compensate for 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 compensate for irregularities in the surface profiles of the individual battery cell containers. The various embodiments described above are merely examples and are not intended to limit the scope of this disclosure in any way. Variations of the innovations described herein are obvious to those 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 subcombinations of features not expressly described above.In addition, features from one or more of the previously described embodiments 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 sub-combinations are obvious to a person skilled in the art upon a comprehensive review of the present disclosure. It is intended that the subject matter described herein and in the stated claims covers and encompasses all suitable modifications of the technology.

Claims

[1] Battery unit (100) comprising: a first battery module (102(1)); a second battery module ( 102(2)), wherein the first battery module (102(1)) and the second battery module (102(1)) are spaced apart from each other; and a heat exchanger (110, 210) arranged between the first battery module (102(1)) and the second battery module (102(2)), with a first side in contact with the first battery module (102(1)) and a second side in contact with the second battery module (102(2)), wherein the heat exchanger (110, 210) defines at least one internal fluid flow passage (118) for transferring a heat exchanger fluid, the first and second sides of the heat exchanger (110) being elastically compressible to adapt to changes in the distance between the first and second battery modules (102(1), 102(2)); wherein the heat exchanger ( 110, 210) has several independently compressible areas that are positioned between and in engagement with the first battery module (102(1)) and the second battery module (102(2)); characterized by , that the first battery module (102(1)) has several battery cell containers (104), each of which accommodates at least one battery cell (106); the second battery module (102(2)) has several battery cell containers (104), each of which accommodates at least one battery cell (106), wherein the battery cell containers (104) of the first battery module (102(1)) are located at a distance from and opposite respective battery cell containers (104) of the second battery module (102(2)) and each of the independently compressible areas is positioned between and in engagement with a respective battery cell container (104) of the first battery module (102(1)) and a respective battery cell container (104) of the second battery module (102(2)), wherein each of the individually compressible areas is adapted to the distance between the battery cell containers (104) between which it is positioned. [2] Battery unit (100) according to claim 1, wherein each of the independently compressible areas defines a flow channel for the heat exchanger fluid through itself. [3] Battery unit (100) according to claim 2, wherein the flow channels are connected in series to form the at least one fluid flow passage, which fluid flow passage is a convoluted passage. [4] Battery unit (100) according to one of claims 1 to 3, wherein the heat exchanger (110) is formed from several laminated plates, wherein a first outer plate forms the first side of the heat exchanger (110) in contact with the first battery module (102(1)) and a second outer plate forms the second side of the heat exchanger (110) in contact with the second battery module (102(2)), and the first and the second outer plate each contain physically separate areas, each associated with a respective independently compressible area of ​​the heat exchanger (110). [5] Battery unit (100) according to claim 4, wherein the first and the second outer plate are coiled plates with adjacent, physically separated areas that are parallel to each other and are connected by U-shaped areas. [6] Battery unit (100) according to claim 4 or 5, wherein the heat exchanger (110) has opposing adapted first and second inner core plates (136, 138), wherein a first outer core plate (132) is attached to the first inner core plate (136), a second outer core plate (134) is attached to the second inner core plate (138), the first outer plate is attached to the first outer core plate (132) and the second outer plate is attached to the second outer core plate (134), the plates together defining an inner flow chamber in each of the independently compressible areas of the heat exchanger (110), the flow chambers each being partially defined by the first outer plate and the second outer plate such that the heat exchanger fluid contacts the first outer plate and the second outer plate when it flows between the battery modules (102(1), 102(2)). [7] Battery unit (100) according to claim 6, wherein the core plates (132, 134, 136, 138) comprise elastically compressible, physically separate core plate areas, each associated with a respective independently compressible area of ​​the heat exchanger (110). [8] Battery unit (100) according to one of claims 1 to 3, wherein the heat exchanger (210) comprises: a first and a second core plate (232, 234) which are arranged opposite each other and define at least one fluid flow passage between them, a first compliant, essentially planar plate structure (230) located between an outer surface of the first core plate (232) and the first battery module (102(1)), and a second compliant, essentially planar second plate structure (233) located between an outer surface of the second core plate (234) and the second battery module (102(2)). [9] Battery unit (100) according to claim 8, wherein the first and the second compliant plate structure (230, 233) each contain opposing adapted plates, each adapted plate having several independently compressible plate areas. [10] according to claim 9, wherein the opposing adapted plates are formed from a thinner material than the first and second core plate ( 232, 234).

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