Corrugated heat exchanger and method therefor

Abstract

A corrugated heat exchanger defines a plurality of peaks and valleys that extend in a vertical direction relative to a normal axis. The corrugated heat exchanger comprises a first and a second panel. The second panel is welded to the first panel via a network of channel seams. A plurality of fluid-formed fluid circulation channels are disposed between the channel seams. The plurality of fluid-formed cooling fluid circulation channels include: a change in orientation relative to the normal axis; at least a portion of a first channel surface and / or a second channel surface that defines the plurality of fluid-formed cooling fluid circulation channels has a three-dimensional surface profile; the plurality of fluid-formed cooling fluid circulation channels includes a change in cross-sectional area; and / or the plurality of fluid-formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions.

Description

CORRUGATED HEAT EXCHANGER AND METHOD THEREFORFIELD OF THE DISCLOSURE

[0001] The present disclosure relates to a heat exchanger for a battery housing.BACKGROUND

[0002] Batteries for electric vehicles (EVs) are typically enclosed in a battery housing and located on the underside of the vehicle. EV battery housings protect a plurality of battery cells within the housing from exposure to water, dust, debris, and other elements as well as harsh external conditions. EV battery housings often include heat exchangers to cool the battery cells, which generate heat during use. Collectively, the plurality of battery cells and the housing can be referred to as a battery pack.

[0003] One particular concern with battery packs is thermal management. Lithium-ion battery cells generate heat during use and, if this heat is not dispersed, the battery performance and life expectancy will be degraded. Cooling EV battery packs can be challenging due to the location, size, and chemical makeup of the battery cells within the battery pack. In some scenarios, overheating can lead to a short circuit where the heat will increase exponentially due to a phenomenon referred to as thermal runaway, causing battery failure. As such, heat exchangers are built into battery housings in an effort to control or moderate thermal conditions.

[0004] Typically, heat exchangers are constructed using a time and resource intensive process including preforming two or more metal plates by joining the plates together via brazing with a fluid circulation cavity or fluid circulation channels therebetween. The brazing process involves melting and flowing a filler metal into a joint and requires specific design features to accommodate the filler metal, which has a lower melting point than the adjoining metal. Forming metal heat exchanges that provide an optimal amount of surface contact with the battery cells can be accomplished via extrusion, which eliminates the brazing process, but limits a fluid circulation cavity or fluid circulation channels design options.

[0005] There is a need for heat exchangers that overcome challenges faced in the field, heat exchangers that provide flexible design options for the fluid circulation cavity and channels therein. There is also a need for heat exchangers that have a three-dimensional profile, to optimize surface contact with the battery cells within a battery pack. There is also a need for methods of forming such heat exchangers that utilize more efficient bonding techniques such as welding, and do not require preforming panels, brazing, or metal extrusion.

[0006] Considering the challenges above and the evolving strategies required to deal with the challenges, there remains a continued need for improved heat exchangers for battery packs.SUMMARY

[0007] An embodiment of a corrugated heat exchanger including a plurality of fluid- formed cooling fluid circulation channels is disclosed. The corrugated heat exchanger defines a normal axis and has a first end and a second end. The corrugated heat exchanger defines a plurality of peaks and valleys extending in a vertical direction relative to the normal axis. The corrugated heat exchanger comprising a first and a second panel. The first panel has a first cooling surface and a first channel surface opposite the first cooling surface. The second panel has a second cooling surface and a second channel surface opposite the second cooling surface. The second panel is welded to the first panel via a network of channel seams and the plurality of fluid-formed cooling fluid circulation channels are formed / disposed between the channel seams. A first port is in fluid communication with the plurality of fluid-formed cooling fluid circulation channels and configured to receive cooling fluid for circulation in the plurality of fluid-formed cooling fluid circulation channels. The second port is in fluid communication with the plurality of fluid-formed cooling fluid circulation channels and configured to expel cooling fluid circulated through the plurality of fluid-formed cooling fluid circulation channels. The plurality of fluid-formed cooling fluid circulation channels include: a change in orientation relative to the normal axis; at least a portion of a first channel surface and / or a second channel surface that defines the plurality of fluid- formed cooling fluid circulation channels has a three- dimensional surface profile; the plurality of fluid-formed cooling fluid circulation channels includes a change in cross-sectional area; and / or the plurality of fluid-formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions.

[0008] In some embodiments, the plurality of fluid-formed cooling fluid circulation channels change orientation at least once by about 10 to 180° in a lateral direction relative to the normal axis.

[0009] In some embodiments, at least a portion of the first channel surface and / or the second channel surface has the three-dimensional surface profile.

[0010] In some embodiments, at least one of the plurality of fluid-formed cooling fluid circulation channels exhibits the change in cross-sectional area as a result in a change of a channel width of the one of the plurality of fluid-formed cooling fluid circulation channels.

[0011] For example, a change in cross-sectional area is further defined as a gradual decrease in cross-sectional area of at least the one of the plurality of fluid-formed cooling fluid circulation channels as the one of the plurality of fluid-formed cooling fluid circulation channels extends from the first port to the second port, e.g. the channel width gradually increases or decrease as the channels extend from the first end to the second end.

[0012] In many embodiments, the first panel and / or the second panel comprises aluminum or an aluminum alloy.

[0013] In some embodiments, the corrugated heat exchanger comprises a first section and a second section oriented substantially parallel to one another. In some such embodiments, the corrugated heat exchanger comprises a return section disposed between the first and the second section, wherein the return section is integral with the first and second sections and at least partially defines the plurality of fluid-formed cooling fluid circulation channels.

[0014] In some embodiments, the plurality of fluid- formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD). In such embodiments, the plurality of fluid cells and the plurality of fluid accelerator portions are defined by the first and the second panel and are formed when the plurality of fluid circulation channels are fluid-formed. The cell depth is typically greater than the accelerator depth. In some embodiments, the cell depth (CD) is defined as the average depth over a length of the cell and the accelerator depth (AD) is defined as the average depth over a length of the accelerator portion, both averages measured centrally in the cooling fluid circulation channel. In other embodiments, the cell depth (CD) is defined as the maximum cell depth of the cell and the accelerator depth (AD) is defined as the minimum cell depth of the accelerator portion. In some embodiments, the cell depth (CD) is greater than about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 times greater than the accelerator depth (AD). In some embodiments, a ratio between the accelerator depth (AD) and the cell depth (CD) is from about 1:2 to about 1 :20.

[0015] In some embodiments, the plurality of fluid- formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions, each ofthe plurality of fluid cells having a cell cross-sectional area (Ccs) and each of the plurality of fluid accelerator portions having an accelerator cross-sectional area (Acs), wherein the Ccs is greater than the Acs- In some embodiments, the Ccs is defined as the average cross-sectional area over a length of the cell and the Acs is defined as the average cross-sectional area over a length of the accelerator portion. In other embodiments, the Ccs is defined as the maximum cross-sectional area of the cell and the Acs is defined as the minimum cross-sectional area of the accelerator portion. The Ccs is typically greater than the Acs- In some embodiments, the Ccs is greater than about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 times greater than the Acs. In some embodiments, a ratio between the Acs and the Ccs is from about 1:2 to about 1:20.

[0016] In some embodiments, the first panel and / or the second panel define a plurality of inter-cell protrusions defining a plurality of internal inter-cell sections in the plurality of fluid-formed cooling fluid circulation channels. The plurality of inter-cell protrusions are configured to penetrate into free space between two adjacent battery cells of a neighboring row. In some such embodiments, the first panel and / or the second panel define a plurality of disturbance elements that extend into at least one of the plurality of fluid-formed cooling fluid circulation channels, wherein the plurality of disturbance elements are arranged in at least one of the plurality of fluid cells and configured to oppose a direction of flow of the cooling fluid.

[0017] Another embodiment of a corrugated heat exchanger includes a plurality of fluid-formed cooling fluid circulation channels, defines a normal axis, and has a first end and a second end. The corrugated heat exchanger defines a plurality of peaks and valleys extending in a vertical direction relative to the normal axis. The corrugated heat exchanger comprises a first panel having a first cooling surface and a first channel surface opposite the first cooling surface and a second panel having a second cooling surface and a second channel surface opposite the second cooling surface. The second panel is welded to the first panel via a network of channel seams and the plurality of fluid-formed cooling fluid circulation channels are formed / disposed between the channel seams. The plurality of fluid-formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD). The cell depth (CD) is greater than the accelerator depth (AD). The plurality of fluid cells define a plurality of internal inter-cell protrusions in the plurality of fluid-formed cooling fluid circulation channels that are configured to penetrate into free space between two adjacent battery cells of a neighboring row.

[0018] An embodiment of a method of making a corrugated heat exchanger is also disclosed. The corrugated heat exchanger has a normal axis, a first end, and a second end, and defines a plurality of fluid-formed cooling fluid circulation channels. The method comprising the steps of: contacting a first panel and a second panel; welding a network of channel seams between the first and second panels; inserting the first and second panels into a mold and forming a plurality of peaks and valleys in the first and second panels; and injecting fluid into the network of channel seams to form the plurality of fluid-formed cooling fluid circulation channels. Each of the plurality of fluid-formed cooling fluid circulation channels are formed / positioned between a first and a second channel seam.

[0019] One embodiment of the method includes the step of deforming and flattening the first and second panels with the network of channel seams subsequent to the step of welding and prior to the steps of molding and injecting.

[0020] One embodiment of the method includes the step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels (a second injection step).

[0021] Some embodiments of the method include the step of forming a three- dimensional surface profile on at least a portion of a first channel surface on the first panel and / or the second channel surface on the second panel prior to the step of welding.

[0022] Some embodiments of the method include the step of injecting forms a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD), wherein the cell depth is greater than the accelerator depth. In some such embodiments, the plurality of fluid cells have inter-cell protrusions configured to penetrate into free space between two adjacent battery cells of a neighboring row. In some such embodiments, the first panel and / or the second panel define a plurality of disturbance elements that extend into the plurality of fluid cells. The plurality of disturbance elements are configured to redirect at least a portion of flow of the cooling fluid towards the inter-cell protrusions.

[0023] In some embodiments, the step of welding forms weld seams such that the plurality of fluid-formed cooling fluid circulation channels include a change in width and / or orientation relative to the normal axis.

[0024] These and other features of the disclosure will be more fully understood and appreciated by reference to the description and the drawings. Before examples of the disclosure are explained in detail, it is to be understood that the disclosure is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure may be implemented in various other examples and of being practiced or being conducted in alternative ways not expressly disclosed herein. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various examples. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the disclosure to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the disclosure any additional steps or components that might be combined with or into the enumerated steps or components.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a top view of an embodiment of a corrugated heat exchanger comprising a plurality of fluid-formed cooling fluid circulation channels.

[0026] Figure 2 is a side view of the corrugated heat exchanger of claim 1 illustrating a plurality of peaks and valleys.

[0027] Figure 3 is a cross-sectional view of the corrugated heat exchanger of Figure 1 at 3-3 illustrating a cross-section of the plurality of fluid-formed cooling fluid circulation channels.

[0028] Figure 4A is a cross-sectional view of a cooling fluid circulation channel of one embodiment of the corrugated heat exchanger.

[0029] Figure 4B is a cross-sectional view of a cooling fluid circulation channel of another embodiment of the corrugated heat exchanger.

[0030] Figure 5 is a perspective view of an embodiment of a corrugated heat exchanger nested between two rows of battery cells.

[0031] Figure 6 is a cross-sectional view of the corrugated heat exchanger of Figure 5 at 6-6 illustrating a plurality of fluid-formed cooling fluid circulation channels.

[0032] Figure 7A is a top view of an embodiment of a corrugated heat exchanger comprising a plurality of fluid-formed cooling fluid circulation channels having a zig-zagging flow path, e.g., a plurality of fluid-formed cooling fluid circulation channels having a change in orientation relative to the normal axis.

[0033] Figure 7B is a top view of another embodiment of a corrugated heat exchanger comprising a plurality of fluid-formed cooling fluid circulation channels having a zig-zagging flow path and exhibiting a 180° change in direction, e.g., a plurality of fluid-formed cooling fluid circulation channels having a change in orientation relative to the normal axis.

[0034] Figure 8 is a perspective view of an embodiment of a corrugated heat exchanger including a first section, a second section, and a return section disposed between the first and the second sections, the corrugated heat exchanger being nested between three rows of battery cells.

[0035] Figure 9 is a cross-sectional view of the corrugated heat exchanger of Figure 8 at 9-9 illustrating a plurality of fluid-formed cooling fluid circulation channels.

[0036] Figure 10 is a top view of an embodiment of a corrugated heat exchanger comprising a plurality of fluid-formed cooling fluid circulation channels having a 180° change in direction at the second end of the corrugated heat exchanger, e.g., a plurality of fluid- formed cooling fluid circulation channels having a change in orientation relative to the normal axis.

[0037] Figure 11 is an isolated top view of one of the plurality of fluid-formed cooling fluid circulation channels of the corrugated heat exchanger of Figure 10, the cooling fluid circulating channel having two changes in a cross-sectional area, each change resulting from a change in channel width.

[0038] Figure 11 A is a cross-sectional slice view of the cooling fluid circulating channel corrugated heat exchanger of Figure at 11 A-l 1 A.

[0039] Figure 1 IB is a cross-sectional slice view of the cooling fluid circulating channel corrugated heat exchanger of Figure at 11B-11B.

[0040] Figure 11C is a cross-sectional slice view of the cooling fluid circulating channel corrugated heat exchanger of Figure at 11C-11C.

[0041] Figure 12 is an isolated top view of three exemplary three-dimensional surface profiles that can be defined by the first channel surface and / or the second channel surface to create fluidic turbulence within the plurality of fluid-formed cooling fluid circulation channels.

[0042] Figure 13 is a top view of an embodiment of a corrugated heat exchangercomprising a first and a second panel welded together via a network of channel seams with a plurality of fluid-formed fluid circulation channels disposed between the channel seams, the first and second panels three-dimensional profile (e.g., being dimpled) to create fluidic turbulence within the plurality of fluid-formed cooling fluid circulation channels.

[0043] Figure 14 is a side view of the corrugated heat exchanger of claim 13 illustrating a plurality of peaks and valleys.

[0044] Figure 15 is a cross-sectional view of the corrugated heat exchanger of Figure 1 at 15-15 illustrating the plurality of fluid- formed cooling fluid circulation channels.

[0045] Figure 16 is a top view of an embodiment of a corrugated heat exchanger comprising a first panel having an exemplary three-dimensional profile to create fluidic turbulence within the plurality of fluid-formed cooling fluid circulation channels.

[0046] Figure 17 is a top view of an embodiment of a corrugated heat exchanger comprising a first panel having another exemplary three-dimensional profile to create fluidic turbulence within the plurality of fluid-formed cooling fluid circulation channels.

[0047] Figure 18A is a partial top side view of an embodiment of a corrugated heat exchanger including a first connector composing a first base welded to a first panel and a first body integral with the first base and defining a first flow chamber and a second connector comprising a second base welded to a second panel and a second body integral with the second base and defining a second flow chamber.

[0048] Figure 18B is a top view of the corrugated heat exchanger of Figure 18 A.

[0049] Figure 19 is side cross-sectional view of a connector comprising a body comprising thermoplastic melt-bonded to a base, wherein the body defines a flow chamber and includes a bonding flange melt-bonded to the base.

[0050] Figure 20 is a side view of an embodiment of a connector including a body comprising thermoplastic melt-bonded to a base wherein the thermoplastic body defines a flow chamber and includes a retaining structure comprising a flange for a coupler.

[0051] Figure 21 is a side view of an embodiment of a connector including a body comprising thermoplastic melt-bonded to a base wherein the thermoplastic body defines a flow chamber and includes a retaining structure for a bayonet coupler.

[0052] Figure 22 is a side view of another embodiment of a connector including a body comprising thermoplastic melt-bonded to a base wherein the thermoplastic body defines a flow chamber and includes a retaining structure configured for spin- welding.

[0053] Figure 23 is side view of another embodiment of a connector comprising a body comprising thermoplastic melt-bonded to a base wherein the thermoplastic body defines a flow chamber and includes a retaining structure configured to directly connect with a hose.

[0054] Figure 24 is a schematic illustration of a first embodiment of a cooling system comprising a manifold and a plurality of corrugated heat exchangers wherein each of the plurality of corrugated heat exchangers include two male and two female connectors, and wherein the male and female connectors of the plurality of corrugated heat exchangers cooperate to form the manifold.

[0055] Figure 25 is a schematic illustration of a second embodiment of a cooling system comprising a manifold and a plurality of corrugated heat exchangers.

[0056] Figure 26 is a schematic illustration of a third embodiment of a cooling system comprising a manifold and a plurality of corrugated heat exchangers.

[0057] Figure 27 is a flow chart illustrating an embodiment of a method of making an embodiment of a corrugated heat exchanger defining a plurality of fluid-formed cooling fluid circulation channels.

[0058] Figure 28 is a flow chart illustrating an embodiment of a method of making a cooling system comprising a manifold and a plurality of corrugated heat exchangers.

[0059] Figure 29 is a schematic illustration of a first and a second panel, which have been welded together via a network of channel seams, inserted in a mold during the step of molding / forming the plurality of peaks and valleys (referred to herein as corrugations) in the first and second panels.

[0060] Figure 29B is a schematic slice cross-sectional view of the first and the second panels of Figure 29 at 29B showing with the first and second panels in the mold, with an inner surface of the mold defining a cavity shaped to help form and define the cross-sectional profile of the plurality of fluid-formed cooling fluid circulation channels of the corrugated heat exchanger.

[0061] Figure 29C is a schematic cross-sectional view of the first and the second panel of Figure 29 at 29C showing a fluid passageway in the first piece of the mold fluid for injecting fluid into the network of channel seams with the first and second panels in the mold prior to forming (e.g., hydroforming) the plurality of fluid-formed cooling fluid circulation channels.

[0062] Figure 30 is a schematic illustration of the components of an embodiment of a corrugated heat exchanger defining a plurality of fluid-formed cooling fluid circulation channels during a method of making a corrugated heat exchanger.

[0063] Figure 31 is a top view of another embodiment of a corrugated heat exchanger comprising a plurality of fluid-formed cooling fluid circulation channels.

[0064] Figure 32 is a side view of the corrugated heat exchanger of claim 31 illustrating a plurality of peaks and valleys.

[0065] Figure 33 is a cross-sectional view of the corrugated heat exchanger of Figure 31 at 33-33 illustrating a cross-section of the plurality of fluid-formed cooling fluid circulation channels.

[0066] Figure 34 is a cross-sectional view of the corrugated heat exchanger of Figure 31 at 34-34 illustrating a cross-section of one of the plurality of fluid-formed cooling fluid circulation channels including include a plurality of fluid cells and a plurality of fluid accelerator portions .

[0067] Figure 35 is an enlarged view of one of the plurality of fluid cells of Figure 34 having a cell depth (CD).

[0068] Figure 36 is an enlarged view of one of the plurality of accelerator portions of Figure 34 having an accelerator depth (AD), the cell depth (CD) of the fluid cell is greater than the accelerator depth.

[0069] Figure 37 is a cross-sectional view of two of an embodiment of a corrugated heat exchanger with battery cells disposed therebetween illustrating a plurality of fluid cells having a first example shape.

[0070] Figure 38 is a cross-sectional view of two of an embodiment of a corrugated heat exchanger with battery cells disposed therebetween illustrating a cross-section showing a plurality of fluid cells having a second example shape.

[0071] Figure 39 is a cross-sectional view of two of an embodiment of a corrugated heat exchanger including a plurality of fluid cells and a plurality of fluid accelerator portions wherein the plurality of fluid-formed cooling fluid circulation channels flow from a first to a second end of the corrugated heat exchanger.

[0072] Figure 40 is a cross-sectional view of two of an embodiment of a corrugated heat exchanger including a plurality of fluid cells and a plurality of fluid accelerator portions wherein the plurality of fluid-formed cooling fluid circulation channels turn 180° in alongitudinal direction at a second end of the heat exchanger and return to the first end.

[0073] Figure 41 is a cross-sectional view of an embodiment of a corrugated heat exchanger wherein the plurality of fluid-formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions, the corrugated heat exchanger includes a first section, a return section having a flow turn of 180° in a vertical direction at a second end of the heat exchanger disposed between the first and the second sections, and a second section, the corrugated heat exchanger having a row of battery cells nested therebetween.

[0074] Figure 42 is a cross-sectional view of a fluid-formed cooling fluid circulation channel in accordance with this disclosure having one or more disturbance elements that extend into at least one of a plurality of fluid-formed cooling fluid circulation channels, wherein the one or more disturbance elements are arranged in the plurality of fluid cells and configured to oppose a direction of flow of the cooling fluid within the fluid- formed cooling fluid circulation channel.

[0075] Figure 43 is a cross-sectional view of the flow of cooling fluid within the fluid- formed cooling fluid circulation channel of Figure 42.

[0076] Figure 44 is a cross-sectional view of a fluid-formed cooling fluid circulation channel in accordance with this disclosure having triangular disturbance elements that extend into at least one of a plurality of fluid-formed cooling fluid circulation channels.

[0077] Figure 45 is a cross-sectional view of a fluid-formed cooling fluid circulation channel in accordance with this disclosure having round disturbance elements that extend into at least one of a plurality of fluid-formed cooling fluid circulation channels.DETAILED DESCRIPTION

[0078] A corrugated heat exchanger and a method of making or manufacturing the corrugated heat exchanger is provided. The corrugated heat exchanger provides temperature control of a battery such as a Li battery included in a battery pack for an EV and is durable and corrosion resistant. While discussed below in connection with a battery heat exchanger for use in a battery housing in an electric vehicle (“EV”), the present method is suitable for a wide range of applications, inside and outside of EV applications, including applications such as heat exchangers for radiators and intercoolers. Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, the corrugated heat exchanger 10 is illustrated and generally designated at 10.

[0079] The corrugated heat exchanger 10 defines a plurality of peaks and valleys that extend in a vertical direction relative to a normal axis AN. The corrugated heat exchanger 10 comprises a first panel 12 and a second panel 14. The second panel 14 is welded to the first panel 12 via a network of channel seams 18. A plurality of fluid-formed cooling fluid circulation channels 16 are disposed between the network of channel seams 18.

[0080] As is described in detail herein, the corrugated heat exchanger 10 typically includes one or more of the following features:(1) the plurality of fluid- formed cooling fluid circulation channels 16 include a change in orientation relative to the normal axis AN;(2) the plurality of fluid-formed cooling fluid circulation channels 16 include a plurality of changes in cross-sectional area; and / or(3) at least a portion of a first channel surface 22 and / or a second channel surface 26 that defines the plurality of fluid-formed cooling fluid circulation channels 16 has a three- dimensional surface profile 28.

[0081] The first panel 12 defines a first cooling surface 20 and the first channel surface 22 opposite the first cooling surface 20 and the second panel 14 has a second cooling surface 24 and the second channel surface 26 opposite the second cooling surface 24. The first and second panels 12, 14 typically comprise a weldable metal or metal alloy. In a preferred embodiment, the first and second panels 12, 14 comprise aluminum or an aluminum alloy that is durable but malleable. The first panel 12, which can be deformed in the process of manufacturing the corrugated heat exchanger 10 and is later molded to a shape described herein can comprise a first type of aluminum or aluminum alloy and the second panel 14, which istypically minimally deformed or not deformed in the process of manufacturing the corrugated heat exchanger 10 described herein can comprise a second type (or a different type) of aluminum or aluminum alloy.

[0082] Prior to manufacturing the corrugated heat exchanger 10, the first and second panels 12, 14 are typically planer or flat. In many embodiments, the first panel 12 typically has a thickness of from about 0.3 to 10 mm, from about 0.4 to 5 mm, or from about 0.5 to 2 mm prior to the manufacturing process. It should be appreciated that the manufacturing process may decrease the thickness of the first panel 12 in areas where deformation of the first panel 12 occurs during the formation of a plurality of fluid- formed cooling fluid circulation channels 16. In many embodiments, the second panel 14 typically has a thickness of from about 0.4 to 8 mm or from about 0.8 to 4 mm prior to the manufacturing process. It should be appreciated that the manufacturing process may decrease the thickness of the second panel 14 in areas where deformation of the second panel 14 occurs (if the second panel 14 is deformed) during the formation of a plurality of fluid-formed cooling fluid circulation channels 16. In the preferred embodiment of the corrugated heat exchanger 10, the first panel 12 is deformed to define a cross-sectional profile and a path of the plurality of fluid-formed cooling fluid circulation channels 16 while the second cooling surface 24 and the second channel surface of the second panel 14 is not deformed (the second panel is however deformed during molding to a corrugated shape).

[0083] In various non-limiting examples, the first and / or second panel 12, 14 comprises a 3000, 5000, or a 6000-grade aluminum alloy. Such alloys tend to be readily weldable with autogenous laser welding. The first and / or second panel 12, 14 can be tempered prior to formation of the corrugated heat exchanger 10 or subsequent to the formation of the corrugated heat exchanger 10. In one non-limiting embodiment, the first and / or the second panel 12, 14 comprises a 3000 grade, tempered alloy.

[0084] In embodiments where the first panel 12 and / or the second panel 14 are heat treated prior to or subsequent to formation of the corrugated heat exchanger 10. As used herein, heat treating is a term that includes several processes such as tempering, solution heat treatment, quenching, and aging, which are used to alter the properties of the first panel 12 and / or the second panel 14, e.g., in embodiments wherein the first panel 12 and / or the second panel 14 comprises aluminum. Heat treating is typically used to increase the strength, hardness, temperature resistance, and durability of the first panel 12 and / or the second panel 14.

[0085] In many embodiments, the first panel 12 and / or the second panel 14 are tempered, i.e., heat treated. The tempering process is a subset of the heat-treating process and often includes aging, e.g., artificial aging. In some embodiments, the first panel 12 and / or the second panel 14 can have a temper selected from: Hl 11, Hl 12, Hl 14, H12, H14, Hl 6, Hl 8, H19, H22, H24, H244, H32, H34, H42, H44, O, Tl, T3, T351, T3510, T4, T451, T4511, T5, T6, T651, T6510, T6511, T66, T7, T73, T7351, T7451, T8, and T9.

[0086] In one embodiment, the first panel 12 or the second panel 14 has a O temper and the other panel has an H12, H14, or H16 temper. For example, in embodiments wherein the first panel 12 or the second panel 14 define all but a linear portion of a cross-sectional profile and a path of the plurality of fluid-formed cooling fluid circulation channels 16, the first panel 12 or the second panel 14 can have a O temper (deformed side) and the other panel can have a H14 temper (flat side). The various tempering selections are defined as follows:• H12 Strain-hardened - 1 / 4 hard.• H14 Strain-hardened - 1 / 2 hard.• Hl 6 Strain-hardened - 3 / 4 hard.• O Annealed - products achieving the required annealed properties after hot forming processes may be designated as O temper. In a typical embodiment the panel raw material in a 3xxx or 5xxx series alloy would have a O, H12 or H14 temper and cold formed after welding.

[0087] In some embodiments, the first and / or the second panel comprise a 6xxx or 7xxx series alloy. In these embodiments, the panels would be welded in the annealed (O) condition and may be cold formed with no subsequent heat treatment or hot formed with a subsequent heat treatment to obtain the corrugated heat exchanger 10 having a T4-T6 temper.

[0088] As is illustrated in the Figures, the corrugated heat exchanger 10 typically comprises a first port 30 in fluid communication with the plurality of fluid-formed cooling fluid circulation channels 16 configured to receive cooling fluid for circulation therein, and a second port 32 in fluid communication with the plurality of fluid-formed cooling fluid circulation channels 16 configured to expel cooling fluid circulated therethrough.

[0089] In some embodiments, the corrugated heat exchanger 10 defines the normal axis AN and has a first end 42 and a second end 44. Figure 1 is a top view of an embodiment of the corrugated heat exchanger 10, which comprises the plurality of fluid-formed cooling fluid circulation channels 16. The corrugated heat exchanger 10 of this embodiment includes a returnsection 46 at the second end 44 wherein the plurality of fluid-formed cooling fluid circulation channels 16 change orientation by about 180° in a lateral direction relative to the normal axis AN. The corrugated heat exchanger 10 defines a plurality of peaks and valleys that extend in a vertical direction relative to a normal axis AN. The plurality of peaks and valleys or corrugations are first illustrated in Figure 2. Figure 2 is a side view of the corrugated heat exchanger 10 of claim 1 illustrating a plurality of peaks and valleys. In the embodiment of Figure 2, a connector 48 comprising a thermoplastic body 50 is melt-bonded to a base 52, which is welded to the first panel 12. In the Embodiment of Figures 1-3, the corrugated heat exchanger 10 includes the first port 30 and the second port 32 opposite one another on each side of the corrugated heat exchanger 10. The first and second port 30, 32 function as a cooling fluid inlet and cooling fluid outlet to the plurality of fluid-formed cooling fluid circulation channels 16.

[0090] The first panel 12 defines the first cooling surface 20 and the first channel surface 22 opposite the first cooling surface 20, and the second panel 14 defines the second cooling surface 24 and the second channel surface 26 opposite the second cooling surface 24. Figure 3 is a cross-sectional view of the corrugated heat exchanger 10 of Figure 1 at 3-3 illustrating the plurality of fluid-formed cooling fluid circulation channels 16. The first channel surface 22 and the second channel surface 26 cooperate to define the fluid-formed cooling fluid circulation channels 16. The plurality of fluid- formed cooling fluid circulation channels 16 are formed with a fluid, a gas, or a liquid (e.g., hydroformed).

[0091] Referring to Figures 4A and 4B, which are isolated, sliced cross-sectional views, at least a portion of the first cooling surface 20 and a portion of the second cooling surface 24 is linear, to optimize contact with the battery cells. In some embodiments, a first linear cooling surface portion 34 width Wpi and / or a second linear cooling surface portion 36 width Wp2 is from 40 to 100, 50 to 90 or from 60 to 80 % of a channel width Wc. The channel width Wc is defined as the distance between the channel seams 18 between which a cooling fluid circulation channel is formed. In the embodiment of Figure 4A, the first linear cooling surface portion 34 width Wpi and / or the second linear cooling surface portion 36 width Wp2 is from 50 to 90 or from 60 to 80 % of the channel width Wc- With the first linear cooling surface portion 34 width Wpi being about 70% of the channel width Cw and the second linear cooling surface portion 36 width Wp2 being about 70% of the channel width Cw.

[0092] In many embodiments, the first cooling surface 20 and / or the second coolingsurface 24 is linear (undeformed by hydroforming), and the other cooling surface has a linear surface portion width from 50 to 90 or from 60 to 80 % of the channel width as defined by the distance between the channel seams 18 between which a cooling fluid circulation channel is formed. For example, in Figure 4B, the first linear cooling surface portion 34 width Wpi is from 50 to 90 or from 60 to 80 % of the channel width (about 70%) and the second linear cooling surface portion 36 is linear, so the second linear cooling surface portion 36 width Wpz is 100% the channel width Wc. The embodiment of Figure 4B, the first panel 12 defines all but a linear portion of a cross-sectional profile of the fluid-formed cooling fluid circulation channels 16 and the second panel 14 defines a linear portion of a cross-sectional profile.

[0093] Figure 5 is a perspective view of an embodiment of the corrugated heat exchanger 10 nested between two rows of battery cells. In Figure 5, the plurality of valleys defined by the first cooling surface 20 receive a plurality of battery cells, and the plurality of valleys defined by the second cooling surface 24 (opposite the plurality of peaks defined by the first cooling surface 20) receive another plurality of battery cells. Figure 6 is a cross-sectional view of the corrugated heat exchanger 10 of Figure 5 at 6-6 illustrating a plurality of fluid- formed cooling fluid circulation channels 16. In the embodiment of Figures 5 and 6, the first and second port 30, 32 are located at the first end and on the same side of the corrugated heat exchanger 10 (in contrast to the embodiment of corrugated heat exchanger 10 of Figure 1 which has the first and second port 30, 32 opposite one another on each side of the corrugated heat exchanger 10. The arrows in Figure 5 illustrate the flow of cooling fluid from the first end 42 of the corrugated heat exchanger 10, to the second end 44 of the corrugated heat exchanger 10, back to the first end 42 of the corrugated heat exchanger 10 - between the first and second port 30, 32.

[0094] In some embodiments, the plurality of fluid- formed cooling fluid circulation channels 16 include a change in orientation in a lateral direction relative to the normal axis AN. In Figures 5 and 6, the plurality of cooling channels change orientation at the second end 44 of the corrugated heat exchanger 10. That is, the corrugated heat exchanger 10 includes the return section 46 at the second end 44 wherein the plurality of fluid- formed cooling fluid circulation channels 16 change orientation by about 180° in a lateral direction relative to the normal axis AN. At the second end 44, the cooling channels change orientation to route the cooling fluid back to the first end 42 of the corrugated heat exchanger 10. The 180° turn of the cooling channels at the second end 44 represents change in orientation in a lateral direction relative to the normal axis AN. In some embodiments, the plurality of fluid-formed cooling fluidcirculation channels 16 change orientation in a lateral direction relative to the normal axis AN one or more times by about 10 to 80°. The 180° turn is integral with the corrugated heat exchanger 10 and defined by the first and second panels 12, 14 as opposed to being defined by a separate component / end piece.

[0095] As is illustrated in the embodiments of Figures 7A and 7B, the plurality of fluid- formed cooling fluid circulation channels 16 can change orientation a plurality of times by about 10 to 80° to create a zig-zagging flow path, which represents change in orientation in a lateral direction relative to the normal axis AN. The corrugated heat exchanger 10 of Figure 7A includes the return section 46 at the second end 44 wherein the plurality of fluid- formed cooling fluid circulation channels 16 change orientation by about 180° in a lateral direction relative to the normal axis AN whereas the corrugated heat exchanger 10 of Figure 7B does not include the return section 46.

[0096] Changing the orientation of the plurality of fluid-formed cooling fluid circulation channels 16 in a lateral direction relative to the normal axis AN is possible because the corrugated heat exchanger 10 is formed via welding and the cooling channels are created via fluid injection. Changes in channel direction / orientation relative to the normal axis (e.g., forming the return section 46) are not possible with extrusion processes.

[0097] In one embodiment, the corrugated heat exchanger 10 comprises a plurality of sections oriented substantially parallel to one another. With reference now to Figures 8 and 9, in some such embodiments, the return section 46 is disposed between a first and a second section 72, 74, wherein the return section 46 is integral with the first and second sections 72, 74 and at least partially defines the plurality of fluid- formed cooling fluid circulation channels 16. Figure 8 is a perspective view of an embodiment of the corrugated heat exchanger 10 including the first section, the second section, and the return section 46 disposed between the first and the second sections. In Figure 8, the corrugated heat exchanger 10 is nestled between three rows of battery cells (the first row of battery cells is made transparent). Figure 9 is a cross- sectional view of the corrugated heat exchanger 10 of Figure 8 at 9-9 illustrating the plurality of fluid-formed cooling fluid circulation channels 16. The return section 47, which is disposed between the first and the second section, is integral with the first and second sections and at least partially defines the plurality of fluid- formed cooling fluid circulation channels 16 as illustrated. In Figure 9, the arrows illustrate the flow of cooling fluid through the corrugated heat exchanger 10. It should be appreciated that in the embodiment illustrated the flow ofcooling fluid through the corrugated heat exchanger 10 is one way, with cooling fluid entering the cooling channels of the heat exchanger through the first port 30 on one side and exiting the cooling channels on the other side of the corrugated heat exchanger 10 through the second port 32. It should be appreciated that various embodiments could, for example, include two ports on each side of the corrugated heat exchanger 10 to allow the flow of fluid different directions within the corrugated heat exchanger 10.

[0098] In some embodiments, the plurality of fluid-formed cooling fluid circulation channels 16 include a plurality of changes in cross-sectional area. The change in cross-sectional area can result from a change of a channel width of the one of the plurality of fluid-formed cooling fluid circulation channels 16. In some examples, the change in cross-sectional area is in an amount of from about 5 to about 50 % based on an initial cross-sectional area of the one of the plurality of fluid-formed cooling fluid circulation channels 16. In one embodiment, the change in cross-sectional area is further defined as a decrease in cross-sectional area of the one of the plurality of fluid-formed cooling fluid circulation channels 16 as the one of the plurality of fluid- formed cooling fluid circulation channels 16 extends from the first port 30 to the second port 32. In another embodiment, the change in cross-sectional area is further defined as an increase in cross-sectional area of the one of the plurality of fluid-formed cooling fluid circulation channels 16 as the one of the plurality of fluid-formed cooling fluid circulation channels 16 extends from the first port 30 to the second port 32. The cross-sectional area of the fluid-formed cooling fluid circulation channels 16 can be varied to adjust fluid flow rates through the fluid-formed cooling fluid circulation channels 16 of the corrugated heat exchanger 10 to optimize cooling.

[0099] Figure 11 is an isolated top view of one of the plurality of fluid- formed cooling fluid circulation channels 16 of the corrugated heat exchanger 10 of Figure 10, the cooling fluid circulating channel having two changes in cross-sectional area, each change resulting from a change in channel width. Figure 11A is a cross-sectional view of the cooling fluid circulating channel of Figure 11 at 11 A- 11 A. Figure 1 IB is a cross-sectional view of the cooling fluid circulating channel of the corrugated heat exchanger 10 of Figure H at l lB-l lB. The channel width illustrated in Figure 1 IB (from weld seam to weld seam) is narrower than the channel width illustrated in Figure 11 A (from weld seam to weld seam). Figure 11C is a cross-sectional view of the cooling fluid circulating channel of the corrugated heat exchanger 10 of Figure 11 at 11C-11C. The channel width illustrated in Figure 11C (from weld seam to weld seam) isnarrower than the channel width illustrated in Figure 1 IB (from weld seam to weld seam). The width of the fluid-formed cooling fluid circulation channels 16 can be varied adjust fluid flow rates through the fluid- formed cooling fluid circulation channels 16 of the corrugated heat exchanger 10 to optimize cooling. Changing the channel width of the fluid- formed cooling fluid circulation channels 16 is possible because the corrugated heat exchanger 10 is formed via welding and the cooling channels are created via fluid injection (e.g. injection of a gas or a liquid), typically while the welded panels are in a mold that has a surface profile that assists formation of the cooling fluid circulation channels 16. Such changes in channel width are not available with extrusion processes.

[0100] In some embodiments at least a portion of the first channel surface 22 and / or the second channel surface 26 that defines the plurality of cooling fluid circulation channels 16 has the three-dimensional surface profile 28. In some embodiments, the three-dimensional surface profile 28 is heterogeneous. In other embodiments, the three-dimensional surface profile 28 is homogeneous. Figure 12 is an isolated top view of three exemplary three- dimensional surface profiles which can be defined by the first channel surface 22 and / or the second channel surface 26 to create fluidic turbulence within the plurality of fluid-formed cooling fluid circulation channels 16. In the examples of Figure 12, the three-dimensional surface profiles are micro profiles that can be created via surface etching. One advantage to the micro profiles such as the examples illustrated is when at least a portion of the first channel surface 22 and / or the second channel surface 26 includes such a micro three-dimensional surface profile (e.g., formed via etching), the first cooling surface and / or the second cooling surface do not define a corresponding three-dimensional surface profile. As such, contact between the first cooling surface and / or the second cooling surface and the battery cells can be optimized.

[0101] In some embodiments, the three-dimensional surface profile 28 comprises a plurality of dimples 56. Figures 13, 14, and 15 illustrate an embodiment of the corrugated heat exchanger 10 having the three-dimensional surface profile 28 comprising the plurality of dimples 56. In this case, the three-dimensional surface profiles are macro profiles that can be formed on the first and / or the second panel 12, 14 prior to welding. Figure 13 is a top view of an embodiment of the corrugated heat exchanger 10 comprising the first and a second panel 12, 14 welded together via the network of channel seams 18 with a plurality of fluid-formed fluid circulation channels 16 disposed between the channel seams, the first and second panels12, 14 defining three-dimensional profile (e.g. being dimpled) to create fluidic turbulence within the plurality of fluid-formed cooling fluid circulation channels 16. Figure 14 is a side view of the corrugated heat exchanger 10 of claim 13 illustrating a plurality of peaks and valleys. As is illustrated in Figure 14, the plurality of dimples 56 extend into the plurality of fluid-formed cooling fluid circulation channels 16, but not away from the cooling surface, this configuration provides better surface contact between the first and the second cooling surfaces 20, 24 and the battery cells. A cross-sectional view of the corrugated heat exchanger 10 of Figure 13 at 15-15 illustrating the plurality of fluid- formed cooling fluid circulation channels 16 is shown in Figure 15 with the plurality of dimples 56 extending into the plurality of fluid- formed cooling fluid circulation channels 16 to create fluid turbulence. In the embodiment of Figure 13-25, the first and second ports 30, 32 are located at the first end and on the same side of the corrugated heat exchanger 10 (in contrast to the embodiment of corrugated heat exchanger 10 of Figure 1, which has the first and second port 30, 32 opposite one another on each side of the corrugated heat exchanger 10).

[0102] Figures 16 and 17 illustrate two more embodiments of the corrugated heat exchanger 10 having the three-dimensional surface profile 28. In Figure 16, the three- dimensional surface profile 28 comprises a plurality of elongated, ovular dimples that extend into the plurality of fluid-formed cooling fluid circulation channels 16 to create fluid turbulence. In the embodiment of the corrugated heat exchanger 10 of Figure 16 the first port 30 and the second port 32 are located on the same side of the corrugated heat exchanger 10. The first and second port 30, 32 function as a cooling fluid inlet and cooling fluid outlet to the plurality of fluid- formed cooling fluid circulation channels 16.

[0103] In Figure 17, the three-dimensional surface profile 28 comprises a plurality of zig-zagging ribs that extend into the plurality of fluid-formed cooling fluid circulation channels 16 to create fluid turbulence. In these examples, the three-dimensional surface profiles are macro profiles that can be formed on the first and / or the second panel 12, 14 prior to welding. In contrast to the embodiment of Figure 16, in the embodiment of the corrugated heat exchanger 10 of Figure 17 the first port 30 and the second port 32 are located opposite one another on each side of the corrugated heat exchanger 10. The first and second ports 30, 32 function as a cooling fluid inlet and outlets to provide and expel cooling fluid to the plurality of fluid-formed cooling fluid circulation channels 16.

[0104] With reference to Figures 31-35, in some embodiments, the corrugated heatexchanger 10 includes a plurality of fluid cells 90 and a plurality of fluid accelerator portions 92. Each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD). In many embodiments, the cell depth (CD) is greater than the accelerator depth (AD). Figure 31 is a top view of the corrugated heat exchanger 10 comprising a plurality of fluid-formed cooling fluid circulation channels 16. Figure 31 shows the normal axis (AN), the vertical axis (Av) and the longitudinal Axis (AL). In the example of Figure 31 , cooling fluid enters a first port 30 at the first end 42 of the corrugated heat exchanger 10 flows to a return section 46 at the second end 44 of the corrugated heat exchanger 10 and flows back and is expelled from a second port 32 at the first end 42 of the corrugated heat exchanger 10. Figure 32 is a side view of the corrugated heat exchanger 10 of claim 31 illustrating the plurality of peaks and valleys in the vertical direction, i.e., corrugations. Figure 33 is a cross-sectional view of the corrugated heat exchanger 10 of Figure 31 at 33-33 illustrating a cross-section of the plurality of fluid-formed cooling fluid circulation channels 16.

[0105] Figure 34 is a cross-sectional view of the corrugated heat exchanger 10 of Figure 31 at 34-34 illustrating a cross-section of one of the plurality of fluid- formed cooling fluid circulation channels 16 including the plurality of fluid cells 90 and the plurality of fluid accelerator portions 92. Figure 35 is an enlarged view of one of the plurality of fluid cells of Figure 34 having a cell depth (CD) and illustrating cooling fluid flow in the fluid cell 90. Figure 36 is an enlarged view of one of the plurality of fluid accelerator portions 92 of Figure 34 having an accelerator depth (AD). The cell depth (CD) of the fluid cell is greater than the accelerator depth (AD) of the accelerator portion. The plurality of fluid cells 90 hold larger volumes of cooling fluid and allow optimized cooling between the corrugated heat exchanger 10 and two rows of adjacent battery cells while the accelerator portions create accelerated coolant flow and improved cooling of the battery cells in adjacent rows.

[0106] With continued reference to Figure 31-35, in some embodiments, the plurality of fluid cells 90 and the plurality of fluid accelerator portions 92 are defined by the first and the second panel 12, 14. The plurality of fluid cells 90 and the plurality of fluid accelerator portions 92 are formed when the plurality of fluid circulation channels are fluid-formed in the mold (e.g., during the steps of inserting the first and second panels into a mold and injecting fluid into the network of channel seams). The mold includes cavities, dimensioned to the desired shape of the plurality of fluid circulation channels, which allows for the formation of aplurality of fluid circulation channels having varying depths and cross-sectional areas. Advantageously, the corrugations obtained make it possible to match the shape of the battery cells. The shape of the plurality of corrugations formed is complementary to that the plurality of fluid cells 90 and the plurality of fluid accelerator portions 92 and maximizes surface contact between two adjacent rows of battery cells.

[0107] The plurality of fluid cells 90 are formed when the plurality of fluid circulation channels are fluid-formed in the mold (e.g., during the steps of inserting the first and second panels into a mold and injecting fluid into the network of channel seams. As such, the shape of the mold can be used to change the shape of the plurality of fluid cells 90. The cross-sectional view of Figure 37 illustrates an embodiment of a cormgated heat exchanger 10a with battery cells disposed therebetween and shows a plurality of fluid cells 90 having a first example shape a. This first example shape a is rounded and does not penetrate too deeply into the gap between adjacent battery cells. The cross-sectional view of Figure 38 illustrates an embodiment of a corrugated heat exchanger 10b with battery cells disposed therebetween and shows a plurality of fluid cells b having a second example shape b. This second shape b is more pointed and penetrates deeper into the gap between adjacent battery cells to optimize contact and cooling.

[0108] In many embodiments, the first panel and / or the second panel define a plurality of inter-cell protrusions 96 defining the plurality of internal inter-cell sections 98 in the plurality of fluid- formed cooling fluid circulation channels 16. Advantageously, the inter-cell protrusions 96 have the function of maximizing the contact surface between the first cooling surface 20 of the first panel and the second cooling surface 24 of the second panel and the surfaces of adjacent rows of battery cells. As a result, the cooling of the rows of battery cells is maximized and temperature differences and pressure losses within the plurality of the plurality of fluid-formed cooling fluid circulation channels 16 are minimized.

[0109] In many embodiments, the first panel and / or the second panel define a plurality of inter-cell protrusions 96 defining the plurality of internal inter-cell sections 98 in the plurality of fluid-formed cooling fluid circulation channels. The inter-cell protrusions 96 are configured to penetrate into free space between two adjacent battery cells of a neighboring row. Preferably, each of the plurality of fluid cells 90 is configured to form, during the step of forming by injection under pressure of a fluid in a mold a plurality of inter-cell protrusions 96 of the first and second panels 12, 14 to penetrate into the free space between two adjacent cells of a row of battery cells.

[0110] Certain embodiments of the corrugated heat exchanger can also include a plurality of disturbance elements 94 that extend into at least one of the plurality of fluid-formed cooling fluid circulation channels 16. The plurality of disturbance elements 94 are arranged in at least one of the plurality of fluid cells and configured to oppose a direction of flow of the cooling fluid. The first panel and / or the second panel typically define the plurality of disturbance elements 94. Figure 42 is a cross-sectional view of a fluid-formed cooling fluid circulation channel 16 in accordance with this disclosure having plurality of disturbance elements 94 that extend into at least one of a plurality of fluid- formed cooling fluid circulation channels 16, wherein the plurality of disturbance elements 94 are arranged in the plurality of fluid cells 90 and configured to oppose a direction of flow of the cooling fluid within the fluid- formed cooling fluid circulation channel 16. Figure 43 is an enlarged cross-sectional view of the flow of cooling fluid within the fluid-formed cooling fluid circulation channel of Figure 42.

[0111] If included the plurality of disturbance elements 94 disturb the flow of the cooling fluid circulating in the plurality of fluid-formed cooling fluid circulation channels 16. The plurality of disturbance elements 94 are arranged in the plurality of fluid-formed cooling fluid circulation channels 16 and configured to locally induce a reduction in the fluid cells and to oppose the direction of flow the cooling fluid therein. Advantageously, the disturbance elements 94 make it possible to mix the cooling fluid in the fluid cells and improve the heat exchange between the cooling fluid and the first and / or second channel surface 22, 26. The disturbance elements 94 make it possible to mix the cooling fluid which is located at the center of the fluid cell with the cooling fluid adjacent the first and second channel surface 22, 26 that define the fluid cell, which is hotter than in the center and improve the heat exchange between the cooling fluid and the channel surfaces. As a result, the temperature variations in the fluid cell are minimized and the thermal regulation of the adjacent battery cells is more homogeneous.

[0112] In some embodiments, like the embodiments of Figures 42-45 wherein the disturbance elements 94 extend vertically along a vertical axis (Av) and substantially perpendicular to a longitudinal axis (AL) and the normal axis (AN). The disturbance elements 94 can have a cross-section that is triangular, rectangular, square, semi-circular, circular, u- shape, or L-shape. In many embodiments, the disturbance elements 94 project from at least one of: the first channel surface 22 of the first panel; and the second channel surface 26 of thesecond panel. The plurality of disturbance elements 94 are, in many embodiments, distributed at regular intervals and / or are spaced two by two by a predetermined spacing distance. Typically, each disturbance element 94 is located in the cavity defined by the fluid cell 90 and is configured to redirect at least a portion of flow of cooling fluid towards the internal intercell section 98 defined by the inter-cell protrusion 96.

[0113] Figure 42 is a cross-sectional view of a fluid-formed cooling fluid circulation channel 16 in accordance with this disclosure including disturbance elements 94 having a triangular shape that extend into the fluid-formed cooling fluid circulation channels 16, wherein the plurality of disturbance elements 94 are arranged in the plurality of fluid cells 90 and configured to oppose a direction of flow of the cooling fluid within the fluid-formed cooling fluid circulation channel 16. Figure 43 is an enlarged cross-sectional view of the fluid-formed cooling fluid circulation channel 16 of Figure 42.

[0114] Figure 44 is a cross-sectional view of a fluid-formed cooling fluid circulation channel 16 in having triangular disturbance elements 94a that extend vertically into at least one of a plurality of fluid-formed cooling fluid circulation channels. The plurality of disturbance elements 94a are arranged in the plurality of fluid cells 90 and configured to oppose a direction of flow of the cooling fluid within the plurality of internal inter-cell sections 98 of the plurality of inter-cell protrusions 96 in the plurality of fluid-formed cooling fluid circulation channels 16.

[0115] Figure 45 is a cross-sectional view of a fluid-formed cooling fluid circulation channel 16 having round disturbance elements 94b that extend vertically into at least one of a plurality of fluid-formed cooling fluid circulation channels 16. The plurality of disturbance elements 94b are arranged in the plurality of fluid cells 90 and configured to oppose a direction of flow of the cooling fluid within the plurality of internal inter-cell sections 98 of the plurality of inter-cell protrusions 96 in the plurality of fluid-formed cooling fluid circulation channels 16.

[0116] Figures 39-41 demonstrate the design flexibility that is provided with the methods described herein. As a first example, Figure 39 is a cross-sectional view of two of an embodiment of a corrugated heat exchanger 10c including a plurality of fluid cells 90 and a plurality of fluid accelerator portions 92 wherein the plurality of fluid-formed cooling fluid circulation channels 16 flow from the first end 42 to the second end 44 of the corrugated heat exchanger 10c. In such embodiments, cooling fluid flows into and the port 32 on the first end42 of the corrugated heat exchanger 10 and is expelled from the port 30 on the second end 44 of the of the corrugated heat exchanger 10.

[0117] As a second example, Figure 40 is a cross-sectional view of two of an embodiment of the corrugated heat exchanger lOd including the plurality of fluid cells 90 and the plurality of fluid accelerator portions 92 wherein the plurality of fluid-formed cooling fluid circulation channels 16 turn 180° in a longitudinal direction in the return section 46 at the second end 44 of the corrugated heat exchanger lOd and returns to the first end 42. In such embodiments, cooling fluid flows into the port 32 on the first end 42 of the corrugated heat exchanger lOd, is redirected 180°C along the longitudinal axis (AL) in the return section 46 at the second end 44, and flows from the second end 44 to the first end 42 and is expelled from the port 30 on the first end 42 of the of the corrugated heat exchanger lOd. The embodiment of Figure 40 includes features of the embodiment of Figures 5 and 6.

[0118] As a third example, Figure 41 is a cross-sectional view of an embodiment of a corrugated heat exchanger lOe including a plurality of fluid cells 90 and a plurality of fluid accelerator portions 92 wherein the plurality of fluid- formed cooling fluid circulation channels 16 include a first section, a return section 47 having a flow turn of 180° in a vertical direction at the second end 44 of the heat exchanger, and a second section the corrugated heat exchanger lOe. The return section 47 is disposed between the first and the second sections. The corrugated heat exchanger lOe is a single, integrated heat exchanger having a row of battery cells nested therebetween. In such embodiments, cooling fluid flows into and the input port 32 on the first end 42 of the corrugated heat exchanger 10 from the first end 42 to the second end 44 of the corrugated heat exchanger lOd through the first section, is redirected 180°C along the vertical axis (Av) in the return section 47 at the second end 44, and flows from the second end 44 to the first end 42 in the second portion and is expelled from the output port 30 on the first end 42 of the of the corrugated heat exchanger lOe. The embodiment of Figure 41 includes features of the embodiment of Figures 8 and 9.

[0119] Figure 18A is a partial top side view of an embodiment of the corrugated heat exchanger 10. The corrugated heat exchanger 10 includes a first connector 48a comprising a first base 52a welded to a first panel 12 of the corrugated heat exchanger 10 and a first body 50a comprising metal. The first body 50a is integral with the first base 52a. The first base 52a defines a first flow chamber, which extends through the first port 30. The corrugated heat exchanger also includes a second connector 48a comprising a second base 52b welded to thesecond panel 14 of the corrugated heat exchanger 10 and a body 50b comprising metal. The body 50b is integral with the second base 52b. The second base 52b and second body 50b define a second flow chamber, which extends through the second port 32. The base 52 and the body typically comprise aluminum or an aluminum alloy, examples of which are described herein. In this example, the first base 50a has a male configuration and the second base 50b has a female configuration and a sealing channel for positioning an O-ring for sealing purposes.

[0120] Figure 18B is a top view of the corrugated heat exchanger 10 of Figure 18 A. In the embodiments of Figures 18A and 18B, the first connector 48a is centrally located on the first end 42 of the first panel 12 of the corrugated heat exchanger 10, and the second connector 48b is centrally located on the first end 42 of the second panel 14 of the corrugated heat exchanger 10. The first connector 48a has a female end and the second connector 48b has a male end. As such, a plurality of the embodiment of the corrugated heat exchanger 10 illustrated in Figures 18A and 18B can be used to assemble a cooling system 70, with the first connector 48a from a first of the corrugated heat exchanger 10 shaped to receive the second connector 48b of another of the corrugated heat exchanger 10. Of course, the length of the first and second connectors 48a and 48b can be varied to accommodate various battery cell configurations.

[0121] Figure 19 is side cross-sectional view of the corrugated heat exchanger 10 including an embodiment of the connector 48 comprising the body 50 comprising thermoplastic melt-bonded to the base 52. The body 50 defines a flow chamber, which extends through a port, which is in fluid communication with the plurality of fluid- formed cooling fluid circulation channels 16. The body 50 comprising thermoplastic defines a flow chamber and includes a bonding flange melt-bonded to the base 52. In many such embodiments, the thermoplastic body 50 is longer and including a bonding flange is melt-bonded to the base 52 and includes a retaining structure 54 for a coupler. That is, the thermoplastic body can have different shape and length and include various types of the retaining structure 54 (e.g., a flange, a male or female end, etc.). The connector 48 can be injection over-molded or hybrid welded to the base 52. In some embodiments, the base 52 includes a bonding surface and the bonding surface including a micro-textured region 38 defining a plurality of undercut channels and the thermoplastic body 50 includes a bonding interface surface. When the thermoplastic body 50 is bonded to the base 52, a portion of the thermoplastic from the bonding interface surface penetrates the plurality of undercut channels in the micro-textured region 38 to form a robustthermoplastic to metal bond.

[0122] In many embodiments, the thermoplastic body 50 includes the retaining structure 54 for a coupler. The retaining structure 54 can be a coupling flange configured for a molded connection, a clip-on connection, a bayonet connection, a spin welded connection, a direct connection with a hose, or another configuration known in the art. Figure 20 is side view of the connector 48 comprising a retaining structure 54 (flange). Figure 20 is side cross- sectional view of the connector 48 comprising the body 50 comprising thermoplastic melt- bonded to the base 52 wherein the body 50 defines a flow chamber and includes a bonding flange melt-bonded to the base 52 and the retaining structure 54 for a coupler. Figure 21 is side view of the connector 48 comprising the retaining structure 54 shaped to couple with a bayonet connector. Figure 22 is a side view of the connector 48 comprising the retaining structure 54 shaped for spin-welding with a connector. Figure 23 is a side view of the connector 48 comprising a retaining structure 54 or fitting comprising a push fit connection shaped to directly connect with a hose which is available through John Guest of West Drayton, UK.

[0123] The cooling system 70 for a battery pack is also disclosed. The cooling system 70 comprises two or more corrugated heat exchangers 10 comprising aluminum and a manifold 60. Each of the two or more corrugated heat exchangers comprises aluminum and has a first end 42 and a second end. Each of the two or more corrugated heat exchangers comprises a first panel and a second panel. The first panel has a first cooling surface and a first channel surface opposite the first cooling surface, the first cooling surface typically defines the first port 30 at the first end 42. The second panel has a second cooling surface and a second channel surface opposite the second cooling surface, the second cooling surface typically defines the second port 32 at the first end 42. The second panel is welded to the first panel via a network of channel seams with a plurality of fluid-formed fluid circulation channels defined by the first and second channel surfaces, disposed between the channel seams, and in fluid communication with the first and second ports. In this embodiment, a first connector is disposed about and in fluid communication with the first port and a second connector is disposed about and in fluid communication with the second port opposite the first connector at the first end 42. When assembled, the manifold 60 comprises a plurality of the first and second connectors of the two or more corrugated heat exchangers.

[0124] As is described above, various embodiments of the corrugated heat exchanger 10 comprise at least one connector comprising a body having male end, and at least oneconnector having a female end. Examples of this embodiment are illustrated in Figures 24 and 25.

[0125] In one embodiment of the cooling system 70, at least one of the two or more corrugated heat exchangers 10 includes the return section 46 at the second end wherein the plurality of fluid-formed cooling fluid circulation channels 16 change orientation by about 180°. More specifically, in the return section 46, the plurality of fluid-formed cooling fluid circulation channels 16 change orientation by about 180° in a lateral direction relative to the normal axis AN.

[0126] Figure 24 is a schematic illustration of such an embodiment of the cooling system 70. In the embodiment of Figure 24, a manifold 60 is formed for supplying cooling fluid to the plurality of the corrugated heat exchanger 10. In this embodiment, each corrugated heat exchanger includes two of the connector 48a with a male configuration and two of the connector 48b with a female configuration - opposite one another. That is, the two connectors 48a on one side are opposite the two connectors 48a on the other side of the corrugated heat exchanger 10. Each of the male and female connectors 48a, 48b of the plurality of corrugated heat exchangers cooperate to form the manifold 60. In this embodiment, the manifold 60 includes two portions and two adjacent supply channels. As is illustrated, the two of a first connector 48a having a male configuration are received by two of a second connector 48b of the second corrugated heat exchanger to for the two supply channels. The two supply channels supply the plurality of fluid-formed cooling fluid circulation channels 16 of each of the corrugated heat exchanger with cooling fluid. As such, each of the first and second connectors 48a, 48b are shaped to engage one another, and are thus shaped to cooperate and form the manifold 60. Of course, the connectors 48a, 48b can, as is illustrated herein and understood in the art, include sealing features such as O-rings and attachment features that allow the connection (mechanical or adhesive) with a corresponding connector. In the particular embodiment illustrated, an adhesive is used to bond and thus connect the first and second connectors 48a, 48b and form the manifold 60. Still referring to Figure 24, the arrows indicate cooling fluid flow, this embodiment of the cooling system 70, each of the corrugated heat exchangers 10 includes the return section 46 at the second end wherein the plurality of fluid- formed cooling fluid circulation channels 16 change orientation by about 180°. This return section 46 is integral with the corrugated heat exchanger 10 and defined by the first and the second panels.

[0127] Figure 25 is a schematic illustration of another such an embodiment of the cooling system 70. In the embodiment of Figure 25, a manifold 60 for supplying cooling fluid to the plurality of the corrugated heat exchanger 10 defines a supply channel and includes a plurality of fluidic couplings 62. In this embodiment, each corrugated heat exchanger 10 includes two of the base 52 and two of the connector 48. Each connector 48a, 48b includes a retaining structure 54, which allows coupling with a respective extension 64a, 64b. The manifold 60, the plurality of fluidic couplings 62, the extensions 64, the connectors 48, the plurality of cooling fluid circulation channels 16 of each corrugated heat exchanger 10 define a network of fluid passageways through which cooling fluid flows to cool off the battery cells. In the embodiment of Figure 25, each corrugated heat exchanger 10 includes the two connectors 48a, 48b on the same side of the corrugated heat exchanger adjacent one another. In this embodiment, the manifold 60 includes two adjacent portions 60a, 60b defining two supply channels, one for cooling fluid input and one for cooling fluid output. The two supply channels supply the plurality of fluid-formed cooling fluid circulation channels 16 of each of the corrugated heat exchanger with cooling fluid. Of course, the connectors 48a, 48b can, as is illustrated herein and understood in the art, include sealing features such as O-rings and attachment features that allow the connection (mechanical or adhesive) of the first and second extensions. Still referring to Figure 25, the arrows indicate cooling fluid flow, this embodiment of the cooling system 70, each of the corrugated heat exchangers includes the return section 46 at the second end wherein the plurality of fluid-formed cooling fluid circulation channels 16 change orientation by about 180°. This return section 46 is integral with the corrugated heat exchanger and defined by the first and the second panels.

[0128] In one embodiment of the cooling system 70, the manifold 60 includes a first manifold 60a, and wherein each of the two or more corrugated heat exchangers 10 also has a third connector 48c disposed about a third port defined by the first panel 12 at the second end 44 and a fourth connector 48c is disposed about a fourth port defined by the second panel 14 at the second end 44, wherein the cooling system further comprises a second manifold 60b comprising a plurality of the third and fourth connectors 48c 48d of the two or more corrugated heat exchangers 10. In some embodiments, at least one of the two or more corrugated heat exchangers 10 includes at least a portion of the first channel surface and / or the second channel surface that defines the plurality of fluid- formed cooling fluid circulation channels has a three- dimensional surface profile. In some embodiments, at least one of the two or more corrugatedheat exchangers includes the plurality of fluid-formed cooling fluid circulation channels defining at least one change in cross-sectional area. In one embodiment of the cooling system, at least one of the two or more corrugated heat exchangers includes a return section 46 at the second end wherein the plurality of fluid-formed cooling fluid circulation channels change orientation (fan out and back in to be received by the first and the second ports).

[0129] Figure 26 is a schematic illustration of such an embodiment of the cooling system 70. In the embodiment of Figure 26, a manifold 60 is formed for supplying cooling fluid to the plurality of the corrugated heat exchanger 10. In this embodiment, each corrugated heat exchanger includes the connector 48a with a male configuration centrally located on the first end 42 on one side and the connector 48b with a female configuration centrally located on the first end 42 on the other side. The connector 48a on the corrugated heat exchanger is configured to mate with the connector 48b on another of the corrugated heat exchanger. That is, each of the male and female connectors of the plurality of corrugated heat exchangers cooperate to form a first portion 60a of the manifold 60 at the first end 42 of the corrugated heat exchangers 10.

[0130] In the embodiment of Figure 26, a second portion 60b of the manifold 60 is also formed at the second end 44 of the corrugated heat exchangers 10 for supplying cooling fluid to the plurality of the corrugated heat exchanger 10. In this embodiment, each corrugated heat exchanger includes the connector 48d with a male configuration centrally located on the second end 44 on one side and the connector 48c with a female configuration centrally located on the second end 44 on the other side. The connector 48c on the corrugated heat exchanger is configured to mate with the connector 48d on another of the corrugated heat exchanger. That is, each of the male and female connectors of the plurality of corrugated heat exchangers cooperate to form the second portion 60b of the manifold 60.

[0131] In the embodiment of Figure 26, the first portion 60a defines the first supply channel on the first end 42, and the second portion 60b defines the second supply channel on the second end 44. As is illustrated, the first connector 46a having a male configuration is received by the second connector 46b of the second corrugated heat exchanger to form the first supply channel. Likewise, the first connector 46d having a male configuration is received by the second connector 46c of the second corrugated heat exchanger to form the first supply channel.

[0132] The two supply channels supply the plurality of fluid- formed cooling fluid circulation channels 16 of each of the corrugated heat exchanger with cooling fluid. As such, each of the first 46a, 46d and second connectors 46b, 46c are shaped to engage one another, and are thus shaped to cooperate and form the manifold 60 including two portion, one on each side of the system. Of course, the connectors can, as is illustrated herein and understood in the art, include sealing features such as O-rings and attachment features that allow the connection (mechanical or adhesive) of the first and second connector. In the particular embodiment illustrated, an adhesive is used to bond and thus connect the first and second connectors and form the manifold 60. Still referring to Figure 26, the arrows indicate cooling fluid flow, this embodiment of the cooling system 70, each of the corrugated heat exchangers includes a first change in orientation as the cooling circulation channels bow outward from the centrally located ports towards the sides of the corrugated heat exchanger for cooling efficiency. That is the cooling circulation channels radiate outward from the ports at the first end 42 and return to the ports at the second end 44 - as is illustrated by arrows designated cooling fluid flow in the illustration of Figure 26.

[0133] In some embodiments, the connector 48, the thermoplastic body 50, the base, and the manifold 60 comprise the thermoplastic composition. In such embodiments, the thermoplastic composition is thermally conductive and includes polyamide 6 (PA6). The thermoplastic composition of these embodiments exhibits good electrical conductivity, electromagnetic shielding (EMI) and radio frequency (RF) shielding characteristics. In many embodiments, the thermoplastic composition comprises polyamide, is thermally conductive and can be injection molded or extruded. As such, the thermoplastic composition provides design freedom and excellent performance in applications previously restricted to metals.

[0134] The thermoplastic composition comprises a polymer selected from polyamide, polyketone, and polypropylene. In some embodiments the thermoplastic composition comprises a polyamide (nylon) selected from the group of polyamide 6, polyamide 11 , polyamide 12, polyamide 46, polyamide 6,6, polyamide 6,10, polyamide 6,12, and polyamide PPA. In a preferred example, the thermoplastic composition comprises polyamide 6 or polyamide 6,6. In some embodiments, the polymer is present in the thermoplastic composition in an amount of from 10 to 100, 35 to 95, or 60 to 85 wt. %, based on 100 parts by weight of the thermoplastic composition.

[0135] Typically, the thermoplastic composition comprises a filler. Exemplary fillersinclude mineral fillers. Some non-limiting examples of mineral filler include particles and fibers comprising barites, calcium carbonate, carbon and carbon black, clays (e.g., kaolin clay), glass, mica, silica, talc, and wollastonite. In many embodiments, the thermoplastic composition comprises a fibrous filler selected from aramid fibers, carbon fibers, cellulose fibers, acrylic fibers, polyvinyl alcohol fibers, glass fibers, carbon nanotubes, and mineral fibers. In some embodiments, the thermoplastic composition comprises glass fibers, carbon fibers, graphite fibers, carbon nanotubes, or combinations thereof. In some embodiments, the filler is present in the thermoplastic composition in an amount of from 1 to 50, 10 to 40, or 15 to 35 wt. %, based on 100 parts by weight of the thermoplastic composition.

[0136] Some non-limiting examples of the thermoplastic composition are available under the trade names of ULTRADUR® and UL TRAM1D®, which are commercially available from BASF of Florham Park, New Jersey. Other non- limiting examples of the thermoplastic composition are available under the trade name FRIANYL®, from Celanese of Dallas, TX. In one specific non-limiting example, the thermoplastic composition comprises ULTRADUR® B3wg6.

[0137] In many embodiments, the thermoplastic composition is flame-resistant. In one such embodiment, the thermoplastic composition complies with UL 94, the Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances testing, is a plastics flammability standard released by Underwriters Laboratories of the United States. The standard determines the material’s tendency to either extinguish or spread the flame once the specimen has been ignited. In some such embodiments the thermoplastic composition can have a UL 94 classification of HB, V-2, V-l, V-0, 5VB, or 5VA.

[0138] In some embodiments, the thermoplastic composition has a specific gravity of from 1.2 to 2.0, 1.3 to 1.4, 1.2 to 1.5, 1.4 to 1.8, 1.5 to 1.7, or 1.55 to 1.65 g / cm3, when tested in accordance with International Organization for Standardization (“ISO”) 1183-1:2019. In many embodiments, the thermoplastic composition has a melting temperature of from 210 to 310, 210 to 300, 260 to 290, or 230 to 290 °C, when tested in accordance with ISO 11357. In many embodiments, the thermoplastic composition has a melt volume-flow rate of from 30 to 40 cm3 / 10 min, when tested in accordance with ISO 1133.

[0139] Referring now to Figure 27, a method 100 of making the corrugated heat exchanger 10 is also disclosed. The method 100 comprises the steps of contacting the first panel 12 and the second panel 14 (102), and welding the network of channel seams 18 between thefirst and second panels 12, 14 (104). Subsequent to the step of welding, the first and the second panels 12, 14 are inserted into a mold, and molded to form a plurality of peaks and valleys in the first and second panels 12, 14 (106). In the mold, fluid is injected into the network of channel seams 18 to form a plurality of fluid-formed cooling fluid circulation channels 16 (108). In one such embodiment, the steps of forming and injecting are conducted simultaneously.

[0140] As set forth above, the method 100 includes the step of contacting the first panel 12 and the second panel 14. Once the first and second panels 12, 14 are contacted, the network of channel seams 18 are welded therebetween. The method 100 may include the step of contacting the first and second panels 12, 14 via the application of pressure adjacent a planned channel seam during the step of welding. That is, during the step of welding, the first and second panels 12, 14 can be pressed against one another via a clamping means synchronistically applied with, i.e., that move with, the laser. Of course all of the areas adjacent the channel seams can be contacted while the channel seams are welded such that the clamping does not move with the laser beam(s). In some embodiments, the step of welding starts in a central region of the first and second panels 12, 14 and gradually progresses towards a periphery of the first and second panels 12, 14 with one or more laser beams.

[0141] In some embodiments of the method 100, the step of welding can be conducted with at least two laser beams (2, 3, 4, 5, 6, etc.). The step of welding can be accomplished via welding the first and second panels 12, 14 with a laser. An autonomous welding system utilizing remote controls can be used to weld the network of channel seams 18 at high speed. Alternatively, a laser head mounted on a robotic arm can be used to weld the network of channel seams 18. Welding parameters such as energy density and positional focus of the laser beam can be adjusted to create channel seams having a width of from about 0.4 to about 2.0 or about 0.7 to about 1.0 mm. The network of channel seams 18 can be formed with high power and speed for manufacturing efficiency. For example, power of greater than about 1 kW and speeds greater than about 6 m / min can be utilized. In some embodiments, the network of channel seams 18 are welded at a speed of from about 8 to about 30 or about 10 to about 20 m / min.

[0142] The step of contacting the first and second panels 12, 14 during the step of welding can be further defined as clamping via vacuum suction and pressing the first and second panels 12, 14 together. The step of contacting reduces the buildup of stress in and between the first and second panels 12, 14 and the formation of interstices and other welddefects that result from thermal expansion by the intense, localized application of energy via the laser. Of course, the buildup of stress in and between the first and second panels 12, 14 and the formation of interstices and other weld defects can, in some embodiments, be reduced further through a step of cooling the first and / or the second panel 12, 14 during the step of welding.

[0143] In some embodiments, the method 100 further comprises the step of deforming and flattening the first and second panels 12, 14 with the network of channel seams 18 subsequent to the step of welding and prior to the steps of molding / forming and injecting. In some such embodiments, a mold 76 is shaped to form the plurality of peaks and valleys and to exert pressure on the first and second panels 12, 14 in areas outside of the network of channel seams 18. As such, after the step of welding, the first and second panels 12, 14 with the network of channel seams 18 therebetween can be flattened. The step of flattening may be conducted via rolling. The step of flattening (1) deforms and flattens the first and second panels 12, 14 with the network of channel seams 18 therebetween; (2) removes surface irregularities and defects from the first cooling surface 20 of the first panel 12 and the second cooling surface 24 of the second panel 14; and, importantly, (3) releases stress or tension that builds in the first and second panels 12, 14 during the step of welding.

[0144] If included, the step of flattening may include one or more passes through a series of rollers on a roll leveler. A roll leveler progressively deforms and flattens the first and second panels 12, 14. As the first and second panels 12, 14 progress through the series of rollers of the roll leveler bending is more severe at the onset but becomes progressively less severe as the panels progress through the rollers. This series or sequence of deformations and flattening is accomplished via roller positioning and spacing. In some embodiments, the top rollers are positioned deeper in the offset between bottom rollers at the start of the series of rollers of the roll leveler (thus the panels are bent more severely) and the top rollers are positioned slightly in the offset between bottom rollers at the end of the series of rollers of the roll leveler (thus the panels are bent less severely). In some embodiments, at least two successive passes through the series of rollers, which are conducted in different orientations. That is, the different passes (one or more) may be oriented between 30° and 90° relative to each other. Alternatively, the step of deforming and flattening comprises at least two passes through the series of rollers, each of at least two passes conducted at an orientation of from about 30° to about 90° different relative to the series of rollers.

[0145] As such, after the step of flattening, the first and the second panels 12, 14 are inserted into a mold, and molding / forming the plurality of peaks and valleys in the first and second panels 12, 14. In some embodiments, the mold 76 includes a first and second piece 76a, 76b, and the first and the second panels 12, 14 are inserted into a mold 76 and stamped under high pressure to form the plurality of corrugations. The step of molding / forming the plurality of peaks and valleys (referred to herein as corrugations) in the first and second panels 12, 14 is illustrated in Figure 29. In Figure 29, the first and second panels, which have been welded together via a network of channel seams are inserted in the mold 76.

[0146] Typically the first and second panels 12, 14 are clamped together during the molding / forming, pressure is exerted on the first and second panels. In such embodiments, pressure can be selectively or uniformly exerted with the first and second panels 12, 14 are clamped together to form the plurality of corrugations. Under pressure occurs when the first panel 12 and second panel 14 typically comprises Al or an Al alloy that is malleable and deforms because of the internal pressure exerted.

[0147] After the step of forming, fluid is injected into the network of channel seams 18 with the first and second panels 12, 14 clamped together to form (e.g., hydroform) the plurality of fluid-formed cooling fluid circulation channels 16. This can be referred to as the primary fluid injection step. In this step, the plurality of fluid-formed cooling fluid circulation channels 16 are formed. Each of the plurality of fluid-formed cooling fluid circulation channels 16 is positioned between a first and a second channel seam and defines the central flow cavity that tapers into a first and a second crevice adjacent the first and the second channel seam. The step of injecting fluid into the network of channel seams 18 may be conducted at a first fluid pressure of from about 4 to about 50, or about 6 to about 30 MPa. Specific fluid pressures adapted to the method 100 depend on the thickness of the panels, the grade of metal / aluminum, and the shape of the plurality of fluid- formed cooling fluid circulation channels 16. In some embodiments, the first fluid pressure is achieved gradually, as fluidic pressure can be slowly increased, pulsed, pulsed increasingly, and varied to ultimately reach the first fluid pressure while minimizing stress on the first and second panels 12, 14 and the channel seams 18 therebetween.

[0148] Typically the first and second panels 12, 14 are clamped together during the step of injecting fluid into the network of channel seams 18. In some embodiments, pressure is exerted on the first panel 12 in areas outside of the network of channel seams 18 to maintaincontact between the first and second panels 12, 14 in these areas to maintain flatness and reduce stress in the areas outside of the network of channel seams 18 of the corrugated heat exchanger 10 while allowing deformation of the first and / or the second panel 12, 14 within the network of channel seams 18 and thus formation of the plurality of fluid-formed cooling fluid circulation channels 16. In such embodiments, pressure can be selectively or uniformly exerted across the cooling surface of the second panel 14.

[0149] In many embodiments, the first and second panels 12, 14 are clamped together and under pressure in a mold. That is, the step of injecting fluid into the network of channel seams 18 is conducted with the first and second panels 12, 14 positioned in the mold. In such embodiments, formation of the plurality of fluid-formed cooling fluid circulation channels 16 under hydraulic pressure occurs when the first panel 12 is deformed into a cavity shaped to define the cross-sectional profile of the plurality of fluid-formed cooling fluid circulation channels 16. The first panel 12, typically comprises Al or an Al alloy that is malleable and deforms because of the internal pressure exerted within the network of channel seams 18. Each of the plurality of fluid-formed cooling fluid circulation channels 16 are formed between two corresponding channel seams and extend between corresponding channel seams with crevices adjacent to the corresponding channel seams and the central flow cavity therebetween.

[0150] In the cross-sectional view of Figure 29B, the second panels of Figure 29 at 29B showing with the first and second panels in the mold, with an inner surface of the mold defining a cavity 80 shaped to help form and define the cross-sectional profile of the plurality of fluid- formed cooling fluid circulation channels of the corrugated heat exchanger. This type of mold configuration, i.e., both inner surfaces defining the cavity 80, forms a cooling fluid circulation channel like that of Figure 4A. In Figure 29B, you can see where the inner surfaces of the first and second piece of the mold 76a, 76b contacts the opposing cooling surfaces 20, 24 of the first and second panels 12, 14 at the channel seams 18 during the step of injecting. The secondary injection step can occur with less pressure on the first and second piece 76a, 76b of the mold 76 or with a gap between the first and second piece 76a, 76b of the mold 76 as explained below. Of course, the cavity on the inner surfaces of the mold can be used to form the plurality of fluid-formed cooling fluid circulation channels 16, the plurality of fluid cells 90, the plurality of fluid accelerator portions 92, etc.

[0151] Figure 29C is a schematic illustration of the first and the second panel of Figure 29 showing a fluid passageway 78 in the first piece 76a of the mold 76 for injecting fluid intothe network of channel seams 18 with the first and second panels 12, 14 in the mold 76 prior to forming (e.g. hydroforming) the plurality of fluid-formed cooling fluid circulation channels 16. This step can be referred to as the primary fluid injection step. In this illustration, you can see the cavity 80 shaped to define the cross-sectional profile of the plurality of fluid-formed cooling fluid circulation channels 16 on the inner surface of the first piece 76a, which helps guide the deformation of the first panel and formation of the plurality of fluid-formed cooling fluid circulation channels 16. This cavity extends across the surface of the first and / or the second piece 76a, 76b and corresponds to the fluid-formed cooling fluid circulation channels 16. In other words, the cavity 80 is partially defined by the inner surfaces of the first and second pieces of the mold 76. With reference back to Figures 4A and 4B, Figure 4A shows a cross- sectional view of a cooling fluid circulation channel which was formed with the cavity on both inner surfaces, while Figure 4B shows a cross-sectional view of a cooling fluid circulation channel which was formed with the cavity on the inner surface of one of the first and or second piece of the mold 76 and the flat inner surface of the other piece of the mold 76.

[0152] In many embodiments, the step of injecting a fluid into the network of channel seams 18 and / or the secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 is conducted with the first and second panels 12, 14 positioned in the mold 76. In a preferred embodiment the steps of forming and injecting fluid into the network of channel seams 18 to form a plurality of fluid-formed cooling fluid circulation channels are both conducted with the corrugated heat exchanger 10 in the mold 76. To this end, the step of injecting a fluid into the network of channel seams 18 and the step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 is conducted with the first and second panels 12, 14 positioned in the mold 76. The inner surfaces of the mold are typically, shaped to facilitate the formation of fluid channels having a desired dimension, e.g., depth and variations thereof. For example, one or both of the mold surfaces that come together can have a fluid circulation path depression formed therein. In such an example, the fluid circulation path depression aligns with the network of channel seams 18. When one of the pieces of the mold have an inner surface having a fluid circulation path depression formed therein, the process can yield fluid-formed cooling fluid circulation channels 16 such as that shown in Figure 4A. When both pieces of the mold have inner surface having a fluid circulation path depression formed therein, the stress and stretching of hydroforming metal, e.g., aluminum or alloy thereof, can be distributed between the first and the second panel can yield fluid- formedcooling fluid circulation channels 16 such as that shown in Figure 4B. The fluid is released from the plurality of fluid-formed cooling fluid circulation channels 16. Fluid is then used to pressurize the plurality of fluid-formed cooling fluid circulation channels 16 in a secondary step. The secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 may be conducted at a second fluid pressure of from about 0.5 to about 10, or about 2 to about 6 MPa.

[0153] In some embodiments, the method 100 further comprises the secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16. This secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 can increase the width of each of the crevices at the weld seams and can prevent crevice corrosion due to stagnation of cooling fluid. In many embodiments, the secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 is conducted in the mold 76. In some embodiments, the mold 76 comprises at least the first and the second piece and the secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 is conducted with the first and second panels 12, 14 of the first and the second piece 76a, 76b of the mold 76 slightly separated with the corrugated heat exchanger 10 therebetween. For example, the secondary step of injecting fluid into the plurality of fluid- formed cooling fluid circulation channels 16 can be conducted with the first and the second pieces 76a, 76b of the mold 76 separated by a distance of from about 0.5 to about 8 mm or from about 1 to about 5 mm. In other embodiments, the secondary step of injecting fluid into the plurality of fluid- formed cooling fluid circulation channels 16 can be conducted with the first and the second piece 76a, 76b of the mold 76 together (not separated), but the clamping force on the first and the second piece 76a, 76b of the mold 76 reduced.

[0154] The secondary step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels 16 is typically conducted at a second fluid pressure that is lower than the first fluid pressure which is injected into the network of channel seams 18. In some embodiments, the second fluid pressure is achieved gradually, as fluidic pressure can be slowly increased, pulsed, pulsed increasingly, and varied to ultimately reach the second fluid pressure in order to achieve a desired crevice separation that minimizes corrosion while minimizing stress on the first and second panels 12, 14 adjacent the network of channel seams 18.

[0155] It is advantageously provided that, during the process of the step of forming the plurality of fluid- formed cooling fluid circulation channels 16 by injecting fluid (which can beliquid or gas) into the network of channel seams 18 between the first and second panels 12, 14 a mold 76 provides a boundary into which the first panel 12 is deformed and thus prevents unnecessary thinning and stretching of the first panel 12 and ultimately provides consistent first panel 12 thickness and cooling fluid circulation channel shape. Once the plurality of fluid- formed cooling fluid circulation channels 16 are formed, the fluid injected into the network of channel seams 18 is released and the corrugated heat exchanger 10 can be remove from the mold 76.

[0156] In some embodiments, the method 100 comprises the step of welding the base 52 comprising metal to the port 30, 32 on the first or the second panel 12, 14. Typically the step of welding the base 52 to a port 30, 32 on the first or the second panel 12, 14 is conducted prior to the step of welding.

[0157] In some embodiments, the method 100 comprises the step of melt-bonding the base 52 comprising thermoplastic to a port 30, 32 on the first or the second panel 12, 14. Typically the step of melt-bonding the base 52 to a port 30, 32 on the first or the second panel 12, 14 is conducted prior to the step of welding.

[0158] Referring now to Figure 30, the various stages of one embodiment of the method of making the corrugated heat exchanger are disclosed. In this embodiment, the first panel defines the port and the micro- textured region 38 is disposed on a first cooling surface of the first panel adjacent the first port. The first image is a slice cross-sectional view illustrating a first panel defining the first port having the micro-textured region 38 disposed about the first port on a first cooling surface. Of course, in the embodiments disclosed herein, the first and or second panel can be provided with one or more ports having the micro-textured region 38 disposed about the one or more ports. Some embodiments may include the steps of (1) forming one or more ports in the first or the second panel and / or (2) micro-texturing region around the one or more ports. The steps of (1) forming one or more ports in the first or the second panel and / or (2) micro-texturing region around the one or more ports are particularly applicable wherein a base comprising the thermoplastic composition is utilized. From a timing perspective, the steps of (1) forming one or more ports in the first or the second panel and / or (2) micro-texturing a region around the one or more ports can occur before the step of contacting the first panel and the second panel. That said, the ports can be formed before the step of contacting, and the step of micro-texturing a region around the one or more ports can occur after the step of contacting, after the step of welding, and even after the step of molding.

[0159] Still referring to Figure 30, the second image illustrates a thermoplastic base that is melt bonded to the micro-textured region 38 disposed about the first port on the first cooling surface. In the second image, the steps of molding the first and second panels 12, 14 to form a plurality of peaks and valleys in the first and second panels 12, 14, and injecting fluid into the network of channel seams 18 to form a plurality of fluid-formed cooling fluid circulation channels 16 have not yet been conducted. It should be noted that the step of meltbonding the base to the panel can occur before or after the step of welding the network of channel seams 18 between the first and second panels 12, 14.

[0160] Referring back to Figure 30, the third image illustrates the corrugated heat exchanger 10 after the steps of molding the first and second panels 12, 14 to form a plurality of peaks and valleys in the first and second panels 12, 14, and injecting fluid into the network of channel seams 18 to form a plurality of fluid-formed cooling fluid circulation channels 16. In the fourth image, a first connector has been either mechanically connected to or melt bonded to the base to provide an input or output for cooling fluid into the plurality of fluid-formed cooling fluid circulation channels 16. The connector can be used to for, or connect to, the manifold, which can supply a plurality of the corrugated heat exchanger 10.

[0161] Of course, in some embodiments, the base comprises metal, and the base is welded to the cooling surface disposed about or around the port prior to the steps of molding the first and second panels 12, 14 to form a plurality of peaks and valleys in the first and second panels 12, 14, and injecting fluid into the network of channel seams 18 to form a plurality of fluid-formed cooling fluid circulation channels 16. In many such embodiments, the base may have or present the micro-textured region, so that the connector can bond with and fluidically seal the flow passage defined by the base and the connector that is in fluid contact with the adjacent port.

[0162] In some embodiments, the method 100 includes the step of melt-bonding a connector 48 comprising the thermoplastic composition to the base 52. The step of meltbonding the connector 48 to the base 52 can be conducted via hot-press welding or ultrasonic welding the connector 48 to the base 52. In embodiments where the base comprises metal, the base may have or present the micro-textured region, so that the connector can bond with and fluidically seal the flow passage defined by the base and the connector that is in fluid contact with the adjacent port. In embodiments where the base comprises the thermoplastic composition, the cooling surface may have or present the micro-textured region, so that thebase can bond with and provide and fluidically seal the flow passage defined by the base and the connector that is in fluid contact with the adjacent port.

[0163] With reference again to the method of Figure 27, in one embodiment of the method 100 of making a corrugated heat exchanger. The corrugated heat exchanger has a normal axis, a first end, and a second end, and defines a plurality of fluid-formed cooling fluid circulation channels. The method comprising the steps of: contacting a first panel and a second panel 102; welding a network of channel seams between the first and second panels 104; inserting the first and second panels into a mold and forming a plurality of peaks and valleys in the first and second panels 106; and injecting fluid into the network of channel seams to form the plurality of fluid-formed cooling fluid circulation channels 108. Each of the plurality of fluid-formed cooling fluid circulation channels are formed / positioned between a first and a second channel seam.

[0164] One embodiment of the method 100 includes the step of deforming and flattening the first and second panels with the network of channel seams subsequent to the step of welding and prior to the steps of molding and injecting.

[0165] One embodiment of the method 100 includes the step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels (a second injection step).

[0166] Some embodiments of the method 100 include the step of forming a three- dimensional surface profile on at least a portion of a first channel surface on the first panel and / or the second channel surface on the second panel prior to the step of welding.

[0167] Some embodiments of the method 100 include the step of injecting forms a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD), wherein the cell depth is greater than the accelerator depth. In some such embodiments, the plurality of fluid cells have inter-cell protrusions configured to penetrate into free space between two adjacent battery cells of a neighboring row. In some such embodiments, the first panel and / or the second panel define a plurality of disturbance elements that extend into the plurality of fluid cells. The plurality of disturbance elements are configured to redirect at least a portion of flow of the cooling fluid towards the inter-cell protrusions.

[0168] In some embodiments of the method 100, the step of welding forms weld seams such that the plurality of fluid-formed cooling fluid circulation channels include a change in width and / or orientation relative to the normal axis.

[0169] Referring now to Figure 28, a method of making a cooling system comprising a manifold and a plurality of corrugated heat exchangers is also disclosed. The method (200)includes the steps of:• forming a plurality of corrugated heat exchangers, each corrugated heat exchanger comprising aluminum and including a plurality of fluid-formed fluid circulation channels in fluid communication with a first and a second port, a first connector disposed about and in fluid communication with the first port, a second connector disposed about and in fluid communication with the second port, the second connector opposite the first connector (202);• engaging a first connector of a first corrugated heat exchanger with a second connector of a second corrugated heat exchanger (204); and• coupling the first connector and the second connector to form a manifold and a fluid circulation path defined by the manifold and each of the plurality of fluid-formed fluid circulation channels of the plurality of corrugated heat exchangers (206).

[0170] In one embodiment, the first connector comprises a male connector body and the second connector comprises a female connector body.

[0171] In one embodiment, the first connector comprises a male connector body and the second connector comprises a female connector body. In one such embodiment, the step of coupling is further defined as using an adhesive to bond an exterior surface of the first male connector of the first corrugated heat exchanger with an interior surface of the second female connector of the second corrugated heat exchanger.

[0172] Statement A: An embodiment of the corrugated heat exchanger includes a plurality of fluid-formed cooling fluid circulation channels. The corrugated heat exchanger defines a normal axis and has a first end and a second end. The corrugated heat exchanger comprises a first and a second panel. The first panel has a first cooling surface and a first channel surface opposite the first cooling surface. The second panel has a second cooling surface and a second channel surface opposite the second cooling surface. The second panel is welded to the first panel via a network of channel seams and the plurality of fluid-formed cooling fluid circulation channels are disposed between the channel seams. The corrugated heat exchanger also comprises a first port in fluid communication with the plurality of fluid-formed cooling fluid circulation channels that is configured to receive cooling fluid for circulation therein. The corrugated heat exchanger also comprises a second port in fluid communicationwith the plurality of fluid-formed cooling fluid circulation channels and configured to expel cooling fluid circulated therethrough. The corrugated heat exchanger defines a plurality of peaks and valleys extending in a vertical direction relative to the normal axis. The corrugated heat exchanger typically includes at least one of the following features: (1) the plurality of fluid-formed cooling fluid circulation channels include a change in orientation relative to the normal axis; (2) at least a portion of the first channel surface and / or the second channel surface that defines the plurality of fluid-formed cooling fluid circulation channels has a three- dimensional surface profile; and (3) the plurality of fluid-formed cooling fluid circulation channels include a change in cross-sectional area.

[0173] Statement B: The corrugated heat exchanger as set forth in Statement A comprising a return section wherein the plurality of fluid-formed cooling fluid circulation channels change orientation by about 180° in a lateral direction relative to the normal axis.

[0174] Statement C: The corrugated heat exchanger as set forth in Statement A or Statement B comprising a plurality of fluid-formed cooling fluid circulation channels that change orientation by about 10 to 80° in a lateral direction relative to the normal axis.

[0175] Statement D: The corrugated heat exchanger as set forth in Statement C can comprise a plurality of fluid-formed cooling fluid circulation channels that change orientation by about 10 to 80° in a lateral direction relative to the normal axis a plurality of times.

[0176] Statement E: The corrugated heat exchanger as set forth in Statement A or B, wherein at least a portion of the first channel surface and / or the second channel surface has a three-dimensional surface profile.

[0177] Statement F: The corrugated heat exchanger as set forth in Statement E, wherein the three-dimensional surface profile is homogeneous.

[0178] Statement G: The corrugated heat exchanger as set forth Statement E, wherein the three-dimensional surface profile is heterogeneous.

[0179] Statement H: The corrugated heat exchanger as set forth in Statement F or G, wherein the three-dimensional surface profile comprises a plurality of dimples.

[0180] Statement I: The corrugated heat exchanger as set forth in Statement A, wherein one of the plurality of fluid-formed cooling fluid circulation channels exhibits the change in cross-sectional area.

[0181] Statement J : The corrugated heat exchanger as set forth in Statement I, wherein the change in cross-sectional area is a result in a change of a channel width of the one of the plurality of fluid-formed cooling fluid circulation channels.

[0182] Statement K: The corrugated heat exchanger as set forth in Statement J, wherein the change in cross-sectional area is in an amount of from about 5 to about 50 % based on an initial cross-sectional area of the one of the plurality of fluid-formed cooling fluid circulation channels.

[0183] Statement L: The corrugated heat exchanger as set forth in Statement J, wherein the change in cross-sectional area is further defined as a decrease in cross-sectional area of the one of the plurality of fluid- formed cooling fluid circulation channels as the one of the plurality of fluid- formed cooling fluid circulation channels extends from the first port to the second port.

[0184] Statement M: The corrugated heat exchanger as set forth in Statement J, wherein the change in cross-sectional area is further defined as an increase in cross-sectional area of the one of the plurality of fluid- formed cooling fluid circulation channels as the one of the plurality of fluid- formed cooling fluid circulation channels extends from the first port to the second port.

[0185] Statement N: The corrugated heat exchanger as set forth in Statement A, wherein the first panel and / or the second panel comprises aluminum or an aluminum alloy.

[0186] Statement O: The corrugated heat exchanger as set forth in Statement M, wherein the first panel and / or the second panel comprises a 5000 or 6000 series aluminum alloy.

[0187] Statement P: The corrugated heat exchanger as set forth in Statement M, wherein the first panel and the second panel are not heat treated prior to or subsequent to formation of the corrugated heat exchanger.

[0188] Statement Q: The corrugated heat exchanger as set forth in Statement A, wherein the first panel and / or the second panel have a temper selected from: Hi l l, Hl 12, Hl 14, H12, H14, H16, H18, H19, H22, H24, H244, H32, H34, H42, H44, O, Tl, T3, T351, T3510, T4, T451, T4511, T5, T6, T651, T6510, T6511, T66, T7, T73, T7351, T7451, T8, and T9.

[0189] Statement R: The corrugated heat exchanger as set forth in Statement A, wherein the first panel or the second panel has a first temper, and the other panel has a second temper.

[0190] Statement S : The corrugated heat exchanger as set forth in Statement A, wherein the first panel or the second panel define all but a linear portion of a cross-sectional profile of the plurality of fluid-formed cooling fluid circulation channels.

[0191] Statement T: The corrugated heat exchanger as set forth in Statement A, further comprising a first section and a second section oriented substantially parallel to one another.

[0192] Statement U: The corrugated heat exchanger as set forth in Statement U, comprising a return section disposed between the first and the second section, wherein the return section is integral with the first and second sections and at least partially defines the plurality of fluid-formed cooling fluid circulation channels.

[0193] Statement AA an embodiment of a method of making a corrugated heat exchanger defining a plurality of fluid- formed cooling fluid circulation channels, a first port, and a second port is disclosed. The method comprising the steps of: contacting a first panel and a second panel; welding a network of channel seams between the first and second panels; inserting the first and second panels into a mold and forming a plurality of peaks and valleys in the first and second panels; and injecting fluid into the network of channel seams to form the plurality of fluid-formed cooling fluid circulation channels, each of the plurality of fluid- formed cooling fluid circulation channels positioned between a first and a second channel seam. In one embodiment of the method of Statement AA the step of forming a first microtextured region on a first cooling surface of the first panel adjacent the first port and / or a second micro-textured region on a second cooling surface of the second panel adjacent the second port is included. The first micro-textured region and / or the second micro-textured region can further comprise a plurality of undercut channels.

[0194] Statement BB, the method of Statement AA further comprising the step of meltbonding a first connector comprising a thermoplastic composition to the first micro-textured region and / or a second connector comprising the thermoplastic composition to the second micro-textured region.

[0195] Statement CC: The method of Statement BB, wherein the step of melt-bonding is further defined as over-molding, ultrasonic welding, or hot press welding the first microtextured region and / or the second thermoplastic connector to the first micro-textured region and / or the second micro-textured region.

[0196] Statement DD: The method of Statement BB further comprising melt-bonding a retaining structure to the first and / or second thermoplastic connector.

[0197] Statement EE: The method of Statement BB, wherein the step of melt-bonding is conducted prior to the steps of inserting and injecting.

[0198] Statement FF: The method of Statement BB, wherein the thermoplastic composition comprises a polymer selected from polyamide, polyketone, and polypropylene.

[0199] Statement GG: The method of Statement BB, wherein the thermoplastic composition comprises glass fibers, carbon fibers, graphite fibers, carbon nanotubes, or combinations thereof.

[0200] Statement HH: The method of Statement BB further comprising the step of welding a base comprising metal to a first region on the first cooling or second cooling surface adjacent the first port; and / or melt bonding a base comprising thermoplastic to a second region on the first or second cooling surface.

[0201] Statement II: The method of Statement HH, wherein the step of welding or the step of melt bonding is conducted prior to the steps of inserting and injecting.

[0202] Statement JJ: The method of Statement HH further comprising the step of meltbonding a thermoplastic body to the base.

[0203] Statement KK: The method of Statement JJ, wherein the step of melt-bonding a thermoplastic body to the base is conducted prior to the step of welding.

[0204] Statement LL: The method of Statement AA, wherein the steps of forming and injecting are both conducted in the mold.

[0205] Statement MM: The method of Statement AA, wherein the mold is shaped to form the plurality of peaks and valleys, and to exert pressure on the first and second panels in areas outside of the network of channel seams.

[0206] Statement NN: The method of Statement AA, further comprising the step of deforming and flattening the first and second panels with the network of channel seams subsequent to the step of welding and prior to the steps of molding and injecting.

[0207] Statement OO: The method of Statement AA, further comprising step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels.

[0208] Statement AAA: An embodiment of a cooling system for a battery pack. The cooling system comprising two or more corrugated heat exchangers comprising aluminum. Each corrugated heat exchanger having a first end and a second end. Each corrugated heat exchanger comprises a first panel having a first cooling surface and a first channel surface opposite the first cooling surface, said first cooling surface defining a first port at the first endand a second panel having a second cooling surface and a second channel surface opposite the second cooling surface, said second cooling surface defining a second port at the first end. The second panel is welded to the first panel via a network of channel seams with a plurality of fluid-formed fluid circulation channels defined by the first and second channel surfaces, disposed between the channel seams, and in fluid communication with the first and second ports. A first connector is disposed about and in fluid communication with the first port and a second connector disposed about and in fluid communication with the second port opposite the first connector at the first end. A manifold comprises a plurality of the first and second connectors of the two or more corrugated heat exchangers.

[0209] Statement BBB: The cooling system as set forth in claim Statement AAA wherein at least one of the two or more corrugated heat exchangers includes a return section at the second end wherein the plurality of fluid-formed cooling fluid circulation channels change orientation by about 180°.

[0210] Statement CCC: The cooling system as set forth in Statement BBB wherein the manifold is referred to as a first manifold, and wherein each of the two or more corrugated heat exchangers also has a third connector is disposed about a third port defined by the first panel at the second end and a fourth connector is disposed about a fourth port defined by the second panel at the second end, wherein the cooling system further comprises a second manifold comprising a plurality of the third and fourth connectors of the two or more corrugated heat exchangers.

[0211] Statement DDD: The cooling system as set forth in Statement AAA, wherein at least one of the two or more corrugated heat exchangers includes at least a portion of the first channel surface and / or the second channel surface that defines the plurality of fluid-formed cooling fluid circulation channels has a three-dimensional surface profile.

[0212] Statement EEE: The cooling system as set forth in Statement AAA, wherein at least one of the two or more corrugated heat exchangers includes the plurality of fluid-formed cooling fluid circulation channels defining at least one change in cross-sectional area.

[0213] Statement AAAA: An embodiment of a method of making a cooling system comprising a manifold and a plurality of corrugated heat exchangers is disclosed. The method includes the steps of: forming a plurality of corrugated heat exchangers, each corrugated heat exchanger comprising aluminum and including a plurality of fluid-formed fluid circulation channels in fluid communication with a first and a second port, a first connector disposed aboutand in fluid communication with the first port, a second connector disposed about and in fluid communication with the second port, the second connector opposite the first connector; engaging a first connector of a first corrugated heat exchanger with a second connector of a second corrugated heat exchanger; and coupling the first connector and the second connector to form a manifold and a fluid circulation path defined by the manifold and each of the plurality of fluid-formed fluid circulation channels of the plurality of corrugated heat exchangers.

[0214] Statement BBBB: The method of claim Statement AAAA, wherein the first connector comprises a male connector body and the second connector comprises a female connector body.

[0215] Statement CCCC: The method of Statement BBBB, wherein the step of coupling is further defined as using an adhesive to bond an exterior surface of the male connector body of the first corrugated heat exchanger with an interior surface of the second female connector body of the second corrugated heat exchanger.

[0216] The above description is that of current examples of the disclosure. Various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all examples of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these examples. For example, and without limitation, any individual element(s) of the described disclosure may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed examples include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present disclosure is not limited to only those examples that include all these features or that provide all the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

CLAIMS1 . A corrugated heat exchanger including a plurality of fluid-formed cooling fluid circulation channels, the corrugated heat exchanger defining a normal axis and having a first end and a second end, the corrugated heat exchanger comprising: a first panel having a first cooling surface and a first channel surface opposite the first cooling surface; and a second panel having a second cooling surface and a second channel surface opposite the second cooling surface, the second panel welded to the first panel via a network of channel seams wherein the plurality of fluid-formed cooling fluid circulation channels are disposed between the channel seams; a first port in fluid communication with the plurality of fluid-formed cooling fluid circulation channels and configured to receive cooling fluid for circulation therein; and a second port in fluid communication with the plurality of fluid-formed cooling fluid circulation channels and configured to expel cooling fluid circulated therethrough; and wherein the corrugated heat exchanger defines a plurality of peaks and valleys extending in a vertical direction relative to the normal axis; and wherein:(1) the plurality of fluid-formed cooling fluid circulation channels include a change in orientation relative to the normal axis;(2) at least a portion of the first channel surface and / or the second channel surface that defines the plurality of fluid-formed cooling fluid circulation channels has a three-dimensional surface profile; and / or(3) the plurality of fluid-formed cooling fluid circulation channels include a change in cross-sectional area.

2. The corrugated heat exchanger as set forth in claim 1, wherein the plurality of fluid-formed cooling fluid circulation channels change orientation at least once by about 10 to 180° relative to the normal axis.

3. The corrugated heat exchanger as set forth in claim 1 , wherein at least a portion of the first channel surface and / or the second channel surface has the three-dimensional surface profile.

4. The corrugated heat exchanger as set forth in claim 1 , wherein at least one of the plurality of fluid-formed cooling fluid circulation channels exhibits the change in cross-sectional area as a result in a change of a channel width of the one of the plurality of fluid- formed cooling fluid circulation channels.

5. The corrugated heat exchanger as set forth in claim 4, wherein the change in cross-sectional area is further defined as a gradual decrease in cross-sectional area of at least the one of the plurality of fluid-formed cooling fluid circulation channels as the one of the plurality of fluid-formed cooling fluid circulation channels extends from the first port to the second port.

6. The corrugated heat exchanger as set forth in any preceding claim, wherein the first panel and / or the second panel comprises aluminum or an aluminum alloy.

7. The corrugated heat exchanger as set forth in claim 1, further comprising a first section and a second section oriented substantially parallel to one another.

8. The corrugated heat exchanger as set forth in claim 7, comprising a return section disposed between the first and the second section, wherein the return section is integral with the first and second sections and at least partially defines the plurality of fluid-formed cooling fluid circulation channels.

9. The corrugated heat exchanger as set forth in claim 1 , wherein the plurality of fluid-formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD), wherein the cell depth is greater than the accelerator depth, wherein the plurality of fluid cells and the plurality of fluid accelerator portions are defined by the first and the second panel and formed when the plurality of fluid- formed cooling fluid circulation channels are fluid-formed.

10. The corrugated heat exchanger as set forth in claim 9, wherein the first panel and / or the second panel define a plurality of inter-cell protrusions defining a plurality of internal inter-cell sections in the plurality of fluid-formed cooling fluid circulation channels, wherein the plurality of inter-cell protrusions are configured to penetrate into free space between two adjacent battery cells of a neighboring row.

11. The corrugated heat exchanger as set forth in claim 9, wherein the first panel and / or the second panel define a plurality of disturbance elements that extend into at least one of the plurality of fluid-formed cooling fluid circulation channels, wherein the plurality ofdisturbance elements are arranged in at least one of the plurality of fluid cells and configured to oppose a direction of flow of the cooling fluid.

12. A corrugated heat exchanger including a plurality of fluid-formed cooling fluid circulation channels, the corrugated heat exchanger defining a normal axis and having a first end and a second end, the corrugated heat exchanger comprising: a first panel having a first cooling surface and a first channel surface opposite the first cooling surface; and a second panel having a second cooling surface and a second channel surface opposite the second cooling surface, the second panel welded to the first panel via a network of channel seams wherein the plurality of fluid-formed cooling fluid circulation channels are disposed between the channel seams; and wherein the corrugated heat exchanger defines a plurality of peaks and valleys extending in a vertical direction relative to the normal axis, wherein the plurality of fluid-formed cooling fluid circulation channels include a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD), wherein the cell depth is greater than the accelerator depth, and wherein the plurality of fluid cells define a plurality of internal inter-cell protrusions in the plurality of fluid-formed cooling fluid circulation channels that are configured to penetrate into free space between two adjacent battery cells of a neighboring row.

13. A method of making a corrugated heat exchanger having a normal axis, a first end, and a second end, and defining a plurality of fluid-formed cooling fluid circulation channels, said method comprising the steps of: contacting a first panel and a second panel; welding a network of channel seams between the first and second panels; inserting the first and second panels into a mold and forming a plurality of peaks and valleys in the first and second panels; and injecting fluid into the network of channel seams to form the plurality of fluid-formed cooling fluid circulation channels, each of the plurality of fluid- formed cooling fluid circulation channels positioned between a first and a second channel seam.

14. The method of claim 13, further comprising the step of deforming and flattening the first and second panels with the network of channel seams subsequent to the step of welding and prior to the steps of molding and injecting.

15. The method of claim 13, further comprising step of injecting fluid into the plurality of fluid-formed cooling fluid circulation channels.

16. The method of claim 13, further comprising the step of forming a three- dimensional surface profile on at least a portion of a first channel surface on the first panel and / or the second channel surface on the second panel prior to the step of welding.

17. The method of claim 13, wherein the step of injecting forms a plurality of fluid cells and a plurality of fluid accelerator portions, each of the plurality of fluid cells having a cell depth (CD) and each of the plurality of fluid accelerator portions having an accelerator depth (AD), wherein the cell depth is greater than the accelerator depth.

18. The method of claim 17, wherein the step of injecting forms the plurality of fluid cells having inter-cell protrusions configured to penetrate into free space between two adjacent battery cells of a neighboring row.

19. The method of claim 18, wherein the first panel and / or the second panel define a plurality of disturbance elements that extend into the plurality of fluid cells and are configured to redirect at least a portion of flow of cooling fluid towards the inter-cell protrusions.

20. The method of claim 13, wherein the step of welding forms weld seams such that the step of hydroforming forms the plurality of fluid-formed cooling fluid circulation channels include a change in width and / or a change in orientation relative to the normal axis.

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