Thermally conductive polymer cooling plates for battery thermal management

Abstract

A cooling plate for thermal management of batteries in a battery pack and a process for forming such a battery pack are provided. The cooling plate includes a composite material formed into the shape of a hollow structure. The composite material has a composition including a thermally conductive filler dispersed within a polymer matrix. The hollow structure has an outer wall having a thickness ranging from about 0.3 millimeters (mm) to about 2.5 mm. The hollow structure includes an upper section in thermal contact with at least one battery, a lower section integrally formed with the upper section, and one or more channels located between the upper and lower sections, the one or more channels configured to allow a fluid to flow therethrough to provide thermal management for the battery.

Description

[Technical Field]

[0001] The present invention relates to cooling plates used to provide thermal management of batteries or battery modules and / or battery packs. [Background technology]

[0002] The statements in this section provide background information related to the present disclosure and definitions of some of the terms used in the disclosure, and do not necessarily constitute prior art.

[0003] Currently, electric vehicles (EVs) and hybrid electric vehicles (HEVs) commonly use aluminum plates to transfer heat between the battery pack and the battery. These plates are typically located at the bottom of the battery pack, which typically contains multiple batteries or battery modules. The plates allow fluid to circulate through them for heat transfer purposes. Common fluid types include water or a water / glycol mixture. Because aluminum plates are electrically conductive, a polymer pad (foam or adhesive layer) is typically placed between the battery and the cooling plate within the battery pack. This pad is in physical contact with both the battery and the cooling plate. The use of this pad also eliminates air gaps caused by assembly tolerances and roughness of the outer surfaces of the battery and the cooling plate. The combination of this pad or adhesive layer with the aluminum plate can negatively impact the cost, assembly, recycling, and weight of the battery pack / cooling plate combination.

[0004] Another type of cooling plate can be formed by using a film or composite foil as a flexible top layer and connecting it to a rigid bottom plate. This film or composite foil has a very thin cross-section, on the order of 100 micrometers or less. The composite foil is inflated like a balloon by the fluid circulating inside. All contact force to the battery is achieved through this inflation technique. However, the performance and durability of this type of cooling plate have yet to be established, as the thin cross-section of the inflatable film has limited thermal conductivity and is susceptible to tearing. Additionally, the thin film or composite foil may not be able to withstand the weight or dynamic forces exerted by the battery it is intended to support. Summary of the Invention [Problem to be solved by the invention]

[0005] It is an object of the present disclosure to overcome the aforementioned drawbacks and to provide an improved cooling plate for use in the thermal management of a battery or battery pack. [Means for solving the problem]

[0006] In this regard, the present disclosure generally includes a cooling plate for thermal management of a battery. The cooling plate includes a composite material formed into the shape of a hollow structure having an outer wall with a thickness ranging from about 0.3 millimeters (mm) to about 2.5 mm. The composite material has a composition including a thermally conductive filler dispersed within a polymer matrix. If desired, the thermally conductive filler may also exhibit a low level of electrical conductivity. The hollow structure includes an upper section in thermal contact with at least one battery, a lower section integrally formed with the upper section, and one or more channels located between the upper and lower sections. To provide thermal management for the battery, the one or more channels are configured to allow fluid to flow therethrough. By allowing fluid to flow through the one or more channels, incorporating the composite material into the hollow structure results in a volume change of less than about 15%. If desired, the hollow structure may be formed as a single piece.

[0007] The thermally conductive filler includes a plurality of particles having a composition selected from the group consisting of boron nitride, alumina, aluminum nitride, silicon nitride, silicon carbide, graphene, carbon nanotubes, and mixtures thereof. The polymer matrix is ​​an elastomer, thermoplastic resin, or thermoplastic elastomer (TPE) having a Shore A hardness of about 40 to 100 or a Shore D hardness of 20 to about 75. The composite composition also includes a plurality of boron nitride particles dispersed in a thermoplastic elastomer (TPE) having a Shore A hardness of about 70 to about 80. The content of the thermally conductive filler may be about 5 wt% to about 25 wt% based on the total weight of the composite.

[0008] According to one aspect of the present disclosure, one or more channels within the hollow structure may include one or more structural elements configured to support the weight of the battery. The structural elements may have a composition different from the composition of the cooling plate. Furthermore, optionally, at least one of the lower section and the upper section may include one or more features configured to increase rigidity and to promote fluid mixing by directing fluid flow. These features may protrude into at least one channel from the upper section, the lower section, or both the upper and lower sections.

[0009] The top section of the cooling plate is flat to maintain at least 50% surface contact with the battery, and may further include one or more bump stops configured to aid in battery placement and retention.

[0010] According to another aspect of the present disclosure, there is provided a battery pack with thermal management, the battery pack including at least one battery and a cooling plate including a composite material formed into the shape of a hollow structure, as described above and further defined herein.

[0011] According to another aspect of the present disclosure, the cooling plate may be used to provide thermal management of at least one battery in an electric vehicle (EV) or hybrid electric vehicle (HEV).

[0012] According to yet another aspect of the present disclosure, there is provided a process for forming a battery pack configured for thermal management. The process includes providing a composite material, processing the composite material in a molding process to form a hollow structure, providing at least one battery, assembling the at least one battery with the hollow structure such that the battery is in thermal contact with an upper section of the hollow structure, and allowing fluid to flow through one or more channels located within the hollow structure. If a molding process is used, the process may utilize one selected from the group consisting of blow molding, injection molding, compression molding, rotational molding, and combinations thereof.

[0013] Optionally, the process may further include forming one or more structural elements in at least one channel of the hollow structure, the structural elements being configured to support the weight of the battery or battery module. These structural elements may be formed by a molding process, such as blow molding, utilizing "ship-in-the-bottle" technology.

[0014] Optionally, the process may further include forming one or more features protruding from the upper section, the lower section, or both the upper and lower sections into the one or more channels to improve stiffness and to direct fluid flow and thereby promote fluid mixing.

[0015] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples set forth herein are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0016] In order to provide a thorough understanding of the present disclosure, various embodiments will now be described by way of example only and with reference to the accompanying drawings, in which the components are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the present invention. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a schematic diagram showing an environmental view of a battery pack including a cooling plate formed in accordance with the teachings of the present disclosure. [Figure 2A] FIG. 2A is a cross-sectional view of the battery pack of FIG. 1 taken along the x-axis, showing the hollow structure of the cooling plate 15 in detail. [Figure 2B] FIG. 2B is a cross-sectional view of another battery pack similar to that shown in FIG. 2A, showing a different configuration of the cooling plate. [Figure 3] FIG. 3 is a cross-sectional view of the battery pack of FIG. 2B with structural elements formed in the channels in accordance with the teachings of the present disclosure. [Figure 4] FIG. 4 is an exploded perspective view of the battery pack of FIG. 1 illustrating the inclusion of protruding features within the channels of the cooling plate in accordance with the teachings of the present disclosure. [Figure 5] FIG. 5 is a perspective view of the lower section of the cooling plate of FIG. 4, highlighting the fluid flow through the features that protrude into the channels. [Figure 6] FIG. 6 is a schematic diagram illustrating the use of composite materials to form the upper section, the lower section, and the sides connecting the upper and lower sections in accordance with the teachings of the present disclosure. [Figure 7] FIG. 7 is a flowchart of a process for forming a battery pack in accordance with the teachings of the present disclosure.

[0018] These figures are provided for illustrative purposes only and are not intended to limit the scope of the invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description is exemplary only and is not intended to limit the present disclosure, its application, or uses. For example, cooling plates manufactured and used in accordance with the teachings described herein are described throughout this disclosure in the context of thermal management of batteries or battery packs in electric vehicles (EVs) or hybrid electric vehicles (HEVs) to more fully explain the structural elements and their uses. Incorporation and use of the cooling plates in other applications, including, but not limited to, other electrical appliances or devices that utilize batteries or battery packs, is also contemplated to be within the scope of this disclosure. It should be understood that throughout the specification and drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0020] As used herein, the term "battery cell" refers to the basic electrochemical unit of a battery, including an anode and a cathode, as well as any components used to convert stored chemical energy into electricity, such as electrodes, separators, and electrolytes. In contrast, the terms "battery" or "battery module" refer to at least one battery cell contained within a housing, along with electrical connections and control and protection electronics. The term "battery pack" refers to a collection of multiple batteries, i.e., multiple battery modules, connected together in series or parallel to increase the voltage or capacity generated by the collection of batteries secured within the housing.

[0021] While embodiments are described herein to allow for a clear and concise specification, it is intended and will be understood that these embodiments may be combined or separated in various ways without departing from the scope of the invention. For example, it will be understood that all preferred features described herein are applicable to all aspects described herein.

[0022] The present disclosure provides a cooling plate for thermal management of a battery. The cooling plate typically includes a composite material having a composition including a thermally conductive filler dispersed within a polymer matrix, the composite material being formed into the shape of a hollow structure. The hollow structure includes an upper section, a lower section, and one or more channels located between the upper and lower sections. At least one of the upper and lower sections of the hollow structure is in thermal contact with at least one battery. In other words, the cooling plate is in thermal contact with a portion of the battery, such as the top, bottom, or side of a battery module. The lower section is integrally formed with the upper section. The one or more channels are configured to allow a fluid to flow therethrough, thereby providing thermal management for the battery.

[0023] A cooling plate formed according to the present disclosure includes a composite material that provides good thermal conductivity between a battery or battery pack and a heat-transfer fluid circulating within the cooling plate. Forming the cooling plate using a polymer matrix with a thermally conductive filler dispersed therein results in a relatively soft and flexible composite material, allowing for efficient heat transfer and eliminating the need for polymer pads or adhesive layers. In this regard, the thermally conductive filler enables good thermal conductivity, and the polymer matrix is ​​sufficiently soft and flexible to directly eliminate gaps and provide good physical contact between the cooling plate and the battery or battery pack. Furthermore, by allowing fluid to flow through one or more channels in the cooling plate, the composite material used to form the hollow structure may undergo a volume change of 20% or less, a volume change of less than 15%, a volume change of about 10% or less, or a volume change of 5% or less. Because the thermally conductive filler may exhibit low electrical conductivity, the use of the composite material may also effectively provide electrical insulation for the battery pack.

[0024] While the cooling plates of the present disclosure do not have the same thermal conductivity as conventional commercially available aluminum cooling plates, the thermal conductivity provided by the composite material can provide the necessary or desired performance for thermal management of a battery pack. Furthermore, cooling plates formed in accordance with the teachings of the present disclosure that include composite materials offer additional advantages over conventional cooling plates, such as lower manufacturing costs, lighter weight, easier assembly, reduced likelihood of short circuits occurring within the battery pack, and in some cases (e.g., compared to adhesive-based options), easier recycling. The process for forming the cooling plates opens up the possibility of commercially viable production of products for smaller markets due to tooling differences and lower investment costs required compared to manufacturing processes associated with conventional cooling plates.

[0025] For purposes of this disclosure, the terms "about" and "substantially" as used herein in connection with measurable numbers and ranges refer to expected variations known to those of ordinary skill in the art (e.g., limits and variability of measurement).

[0026] For purposes of this disclosure, the terms "at least one" and "one or more of" may be used interchangeably and may be synonymous. These terms refer to the inclusion of a single element or multiple elements, and may be expressed by adding an "s" suffix after the element. For example, "at least one channel," "one or more channels," and "channel(s)" may be used interchangeably and intended to be synonymous.

[0027] Referring to FIG. 1 , a battery pack 1 is shown with three batteries 5, each having a positive terminal 30 (+) and a negative terminal 30 (−), disposed within a housing 10 associated with the battery pack 1. A cooling plate 15 is positioned such that its upper section 20 is in thermal contact with at least one or all of the batteries 5 in the battery pack 1. As shown in FIG. 1 , to more clearly illustrate the structure and use of the cooling plate 15, the cooling plate 15 is depicted in contact with the underside of a battery or battery module. However, it would not depart from the scope of this disclosure to have the cooling plate inverted so that its upper section 20 is in contact with the top surface of the battery 5 or battery module 5. Similarly, the cooling plate 15 may be configured such that its upper section 20 is in thermal contact with one or more side surfaces of the battery or battery module, as needed or desired for a particular application.

[0028] The surface of the upper section 20 of the cooling plate 15 is generally flat to improve thermal contact and / or heat transfer with the batteries 5. The upper section 20 of the cooling plate 15 may also include one or more bump stops 25 or bosses configured to aid in the placement and retention of the batteries 5 within the battery pack 1.

[0029] As shown in FIG. 1 , the use of composite materials to form the cooling plate provides sufficient performance for the upper section 20 of the cooling plate 15 to conform and establish contact with the battery 5, overcoming any surface roughness or irregularities that may be inherently present. The upper section 20 of the cooling plate 15 can maintain at least 50% surface contact with the battery 5. Alternatively, the surface contact maintained by the cooling plate 15 with the battery 5 can be between 50% and 100%, greater than 50% but less than 100%, between 55% and 95%, or from about 60% to about 90%. For purposes of this disclosure, the term “between” is intended to include the limits of the specified range.

[0030] 2A, a cross-sectional view of the battery pack 1 of FIG. 1 taken along the x-axis is shown, depicting the hollow structure of the cooling plate 15 in greater detail. More specifically, in addition to the upper section 20 being in thermal contact with the battery 5, the lower section 35 is integrally formed with the upper section 20 and further depicts one or more channels 40 through which a fluid 45 flows, thereby providing thermal management for the battery 5. The cooling plate 15 shown in FIG. 2A has three channels 40 formed therein, with solid structures 50A formed between the channels 40 that separate each other and provide structural support to the cooling plate 15, thereby enabling the entire mass of the battery 5 to be supported.

[0031] For purposes of this disclosure, the term "integrally formed" means that the upper section 20 and the lower section 35 are molded or formed as a single piece and / or are joined together to form a "leak-tight" hollow structure using one or more of ultrasonic welding, spin welding, vibration welding, hot plate welding, infrared welding, laser welding, and an overmolding process. Alternatively, the cooling plate 15 may be formed as a single piece. Any process known to those skilled in the art capable of forming a single piece from a composite material may be used, including, but not limited to, injection molding or blow molding.

[0032] The cooling plate's hollow structure is formed to have an outer wall thickness (t) ranging from about 0.3 millimeters (mm) to about 2.5 mm. Alternatively, the wall thickness (t) may range from about 0.5 mm to about 2.3 mm, or from about 1.0 mm to about 2.0 mm. The wall thicknesses (t) of the upper section 15, the lower section 35, and the side portions (s) connecting the upper section 15 and the lower section 35 may be the same or different depending on the structural design and manufacturing parameters used for a particular application. For example, the selection of wall thickness may vary depending on the thickness required to provide sufficient rigidity to support the weight of the battery and to maintain stress levels within the cooling plate's structure below the yield stress of the composite material used to form those structures.

[0033] Referring to FIG. 2B, a cross-sectional view of a battery pack 1 similar to that shown in FIG. 2A is shown in which the solid structural support 50A (see FIG. 1) has been replaced with a sloped structural support 50B. Such a sloped structural support 50B design may be desirable depending on the manufacturing process (e.g., blow molding, etc.) selected to be used to form the cooling plate 15. Using the sloped structural support 50B design results in a small area (a) where there is no thermal contact between the upper section 20 of the cooling plate 15 and the battery 5, resulting in very limited or no heat transfer. The presence of this small area (a) does not affect the ability of the cooling plate 15 to provide thermal management for the battery 5, as previously described, provided that overall surface contact of 50% or more is maintained between the upper section 20 of the cooling plate 15 and the battery 5.

[0034] Referring to FIG. 3, a cross-sectional view of the battery pack 1 having the cooling plate incorporated in FIG. 2 is shown, with structural elements 55 included in one or more channels 40 in the cooling plate 15. The structural elements 55 are configured to assist the cooling plate 15 in supporting the weight of the battery 5. The structural elements may be made of the same material as the cooling plate 15, a different material, or a combination thereof. Alternatively, the structural elements may be made of high-density polyethylene (HDPE). These structural elements may be made as separate pieces and incorporated into the cooling plate during formation of the hollow structure using any process configured for such purpose, including, but not limited to, the use of a "ship-in-the-bottle" technique in a blow molding process.

[0035] Referring to FIG. 4 , a perspective view of a battery pack 1 according to another embodiment of the present disclosure is shown. This perspective view highlights that the lower section 35 may be contoured to control flow and provide additional rigidity. In this regard, the lower section 35 may include one or more features 60 configured to enhance rigidity and promote fluid mixing by directing fluid flow. These features 60 protrude into one or more channels from the lower section 15, the upper section, or both, as shown in FIG. 4 . The shape of the features 60 may be, but is not limited to, cylindrical, elliptical, or angular. The number, shape, and placement of the features 60 are selected to achieve desired flow and / or mixing of fluids within the channels. In FIG. 5 , flow paths 65 that provide fluid mixing in the presence of features 60 protruding into one or more channels of the cooling plate 15 of FIG. 4 are shown schematically with respect to the features 60 protruding from the lower section 35 of the cooling plate 15. The fluid may include any type of heat transfer liquid, including, but not limited to, water, glycol, or a water / glycol mixture.

[0036] 6, the cooling plate's top section 15, bottom section 35, and side(s) connecting the top section 15 and bottom section 35 generally comprise a composite material 70. The composite material 70 consists essentially of, consists of, or comprises a thermally conductive filler 75 dispersed within a polymer matrix 80. The thermally conductive filler 75 may exhibit low electrical conductivity to aid in the electrical insulation of the battery. For purposes of this disclosure, a thermally conductive filler exhibits low electrical conductivity of 9.9×10 5 S / m order or less, or 9.9 x 10 4 The electrical conductivity of the thermally conductive filler is defined as being on the order of S / m or less. Alternatively, the electrical conductivity of the thermally conductive filler is low enough to be classified as an electrical insulator.

[0037] The thermally conductive filler 75 includes a plurality of particles, the composition of which may include boron nitride, alumina, aluminum nitride, silicon nitride, silicon carbide, graphene, graphite, carbon nanotubes (single-walled or multi-walled), or mixtures thereof. The particles may have shapes including, but not limited to, spherical, flat (e.g., platelet-like), irregular, or elongated (e.g., fibrous) shapes. The particles may be described as particles having any achievable crystalline morphology that provides thermal conductivity. Alternatively, boron nitride used as a thermally conductive filler provides desirable levels of thermal conductivity and electrical insulation for use in many applications. Boron nitride (BN) particles used as a thermally conductive filler may have either a hexagonal (H-BN) or cubic (C-BN) crystalline structure, and the thermally conductive filler may be H-BN.

[0038] 6, the polymer matrix 80 comprises an elastomer, thermoplastic resin, or thermoplastic elastomer (TPE) having a Shore A hardness ranging from about 40 to 100, or a Shore D hardness ranging from 20 to about 75. Alternatively, the polymer matrix is ​​a thermoplastic elastomer (TPE), which may have a Shore A hardness ranging from about 50 to about 90, or a Shore D hardness ranging from about 45 to about 75, or may have a Shore A hardness ranging from about 70 to about 80. The Shore A hardness and / or Shore D hardness may be measured by a Shore® (Durometer) test in accordance with ASTM D22440 00, ISO 7619, and ISO 868; DIN 53505; and / or JIS K 6301 (which has been replaced by JIS K 6253). Alternatively, the polymer matrix may be a thermoplastic resin having a Shore D hardness in the range of about 60-75.

[0039] The TPE used as the polymer matrix 80 may include, but is not limited to, styrenic block copolymers (TPE-S), polyolefin blends (TPE-O), thermoplastic polyurethanes (TPE-U), thermoplastic polyester copolymers (TPE-E), thermoplastic polyamides (TPE-A), or mixtures thereof. Alternatively, the thermoplastic resin used as the polymer matrix 80 is high-density polyethylene (HDPE). The polymer matrix is ​​selected based on a combination of properties, including, but not limited to, hardness, cost, environmental impact, and available processing methods for forming the hollow structure of the cooling plate. The type of polymer matrix selected for a particular application may affect the wall thickness (t) of the cooling plate to achieve the necessary compatibility for ensuring the necessary or desired contact with the battery. According to one aspect of the present disclosure, the composition of the composite material 70 includes a plurality of boron nitride particles dispersed within a thermoplastic elastomer (TPE) having a Shore A hardness ranging from about 70 to about 80.

[0040] The thermally conductive filler 75 may be dispersed within the polymer matrix 80 using any known mixing technique for dispersing solid particles in a liquid polymer. Upon mixing, the thermally conductive filler 75 content ranges from about 5% to about 30% by weight, based on the total weight of the composite material 70. Alternatively, the thermally conductive filler 75 content may range from about 5% to about 25% by weight, or from about 10% to about 20% by weight, based on the total weight of the composite material 70.

[0041] According to another aspect of the present disclosure, a battery pack with thermal management is provided. Referring again to Figures 1-6, the battery pack generally includes at least one battery and a cooling plate configured as described above and as further defined in this section. This double-walled enclosure 3 may be used to provide thermal management for at least one battery in an electric vehicle (EV) or hybrid electric vehicle (HEV).

[0042] 7, according to another aspect of the present disclosure, there is provided a process 100 for forming a battery pack configured as described above and further defined herein. The process 100 generally includes the steps of providing a composite material 105, processing the composite material in a molding process to form a hollow structure 110, providing at least one battery 115, assembling the at least one battery with the hollow structure 120 such that the battery is in thermal contact with an upper section of the hollow structure, and allowing fluid to flow through one or more channels located within the hollow structure 125. The molding process 110 may typically be one selected from the group consisting of blow molding, injection molding, compression molding, rotational molding, and combinations thereof.

[0043] If it is desired to form the upper and lower sections of the cooling plate separately, the process 100 may optionally include a bonding step 130. This bonding step 130 may include bonding the upper and lower sections 35 together using any one or more of ultrasonic welding, spin welding, vibration welding, hot plate welding, infrared welding, laser welding, and overmolding techniques to form a "leak-tight" hollow structure.

[0044] If a structural element configured to support the weight of a battery is incorporated into at least one channel in the cooling plate, the process may optionally include an additional forming step 135 to create the structural element, including, but not limited to, the "ship-in-the-bottle" technique used in a blow molding process.

[0045] Finally, if the upper section, lower section, or both incorporate one or more features that protrude into one or more channels of the cooling plate to increase rigidity and / or direct fluid flow and thereby promote fluid mixing, the process may optionally include an additional forming step 140 to create such features. This additional forming step 140 is typically incorporated into the molding process 110 by including an additional step in creating the mold used in the molding process, such as using 3D printing or placing an insert within the mold.

[0046] Given this disclosure, those skilled in the art will understand that many modifications can be made to the specific embodiments disclosed herein and still achieve the same or similar results without departing from or exceeding the spirit or scope of the present disclosure. For example, while the cooling plate and manufacturing process depicted in FIGS. 1 through 7 show a configuration in which the upper section of the cooling plate contacts the bottom of the batteries or battery modules in a battery pack, those skilled in the art will understand that the cooling plate may be inverted, so that its upper section contacts the top surface of the batteries or battery modules, without departing from the scope of the present disclosure. Similarly, if necessary or desirable for a particular application, the cooling plate may be configured to make thermal contact with one or more sides of the batteries or battery modules in a battery pack. Those skilled in the art will understand that any properties described herein are properties that are routinely measured and can be obtained by several different methods. The methods described herein are representative of such and other methods, and other methods may be used without departing from the scope of the present disclosure.

[0047] The foregoing description of various aspects of the present invention has been presented for purposes of illustration and description. It is not exhaustive and is not intended to limit the invention to the precise form disclosed. Many modifications or variations are possible in light of the above teachings. The form discussed was chosen and described in order to best illustrate the principles of the invention and its practical application, thereby enabling those skilled in the art to utilize the invention in various forms and with various modifications suited to the particular use contemplated. Therefore, the present invention is not limited to the preferred exemplary embodiment described above. Rather, numerous variations utilizing the illustrated solutions are possible, even in fundamentally different embodiments. All such modifications and variations are within the scope of the present invention, as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

1. A cooling plate for thermal management of a battery, comprising: a composite material formed into the shape of a hollow structure; The composite material has a composition including a thermally conductive filler dispersed within a polymer matrix; the hollow structure has an outer wall having a thickness ranging from about 0.3 millimeters (mm) to about 2.5 mm; The hollow structure is an upper section in thermal contact with the at least one battery; a lower section integrally formed with said upper section; one or more channels located between the upper section and the lower section; the one or more channels are configured to allow fluid to flow therethrough to provide thermal management of the battery. Cooling plate.

2. the thermally conductive filler comprises a plurality of particles having a composition selected from the group consisting of boron nitride, alumina, aluminum nitride, silicon nitride, silicon carbide, graphene, carbon nanotubes, and mixtures thereof; The cooling plate of claim 1 .

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

4. The composite composition includes a plurality of boron nitride particles dispersed in a thermoplastic elastomer (TPE) having a Shore A hardness ranging from about 70 to about 80. The cooling plate according to any one of claims 1 to 3.

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

6. the one or more channels include a structural element configured to support the weight of the battery. The cooling plate according to any one of claims 1 to 5.

7. at least one of the lower section and the upper section includes one or more features configured to increase stiffness and to promote mixing of fluids by directing fluid flow; the one or more features protrude into the at least one channel from the upper section, the lower section, or both the upper section and the lower section; The cooling plate according to any one of claims 1 to 6.

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

9. the upper section includes one or more bump stops configured to assist in battery placement and retention; The cooling plate according to any one of claims 1 to 8.

10. The thickness of the outer wall ranges from about 1.0 mm to about 2.0 mm. The cooling plate according to any one of claims 1 to 9.

11. the structural element has a composition different from the composition of the cooling plate; The cooling plate of claim 6 .

12. the hollow structure undergoes a volume change of less than about 15% upon fluid flow through the one or more channels; The cooling plate according to any one of claims 1 to 11.

13. the hollow structure is formed as a single piece; The cooling plate according to any one of claims 1 to 12.

14. The thermally conductive filler content ranges from about 5 wt % to about 25 wt % based on the total weight of the composite material. The cooling plate according to any one of claims 1 to 13.

15. A battery pack with thermal management, comprising at least one battery and a cooling plate according to any one of claims 1 to 14, the cooling plate includes a composite material formed into a hollow structure; The composite material has a composition including a thermally conductive filler dispersed within a polymer matrix; the hollow structure has an outer wall having a thickness ranging from about 0.3 millimeters (mm) to about 2.5 mm; The hollow structure is an upper section in thermal contact with the at least one battery; a lower section integrally formed with said upper section; one or more channels located between the upper section and the lower section; the one or more channels are configured to allow fluid to flow therethrough to provide thermal management of the battery pack. Battery pack.

16. the thermally conductive filler comprises a plurality of particles having a composition selected from the group consisting of boron nitride, alumina, silicon nitride, graphene, carbon nanotubes, and mixtures thereof; the polymer matrix is ​​an elastomer, thermoplastic or thermoplastic elastomer (TPE) having a Shore A hardness in the range of about 40 to 100, or a Shore D hardness in the range of 20 to about 75; The thermally conductive filler content ranges from about 5 wt % to about 25 wt % based on the total weight of the composite material.

16. The battery pack of claim 15.

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

18. 17. A process for forming a battery pack configured for thermal management according to claim 15 or 16, comprising: Providing a composite material; processing said composite material in a molding process to form a hollow structure; providing at least one battery; assembling the at least one battery with the hollow structure such that the battery is in thermal contact with the upper section of the hollow structure; and allowing fluid to flow through one or more channels located within the hollow structure. process.

19. The molding process is one selected from the group consisting of blow molding, injection molding, compression molding, rotational molding, and combinations thereof.

20. The process of claim 18.

20. forming, in at least one channel, one or more structural elements configured to support the weight of the battery, the one or more structural elements having a composition different from the composition of the cooling plate; and / or forming one or more features that protrude from the upper section, the lower section, or both the upper and lower sections into the one or more channels, the one or more features being configured to increase stiffness and to direct fluid flow and thereby promote fluid mixing; 20. The process of claim 18 or 19.

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