Cooling plate having multiple mini-channels

Abstract

This cooling plate assembly comprises a first plate having a first protruding manifold portion and a plurality of protruding cooling fluid passages. Each of the protruding cooling fluid passages comprises a first elongated portion extending parallel from the first protruding manifold portion and directly from the first protruding manifold portion to a U-turn bent region. The U-turn bent region connects a second elongated portion to the first elongated portion. The second elongated portion includes an end portion having a land region between the end portion and the protruding manifold portion. The second plate is attached to the outer periphery of the first plate and the land of the first plate. The second plate includes a plurality of penetration openings overlapping with one end portion of the plurality of protruding cooling fluid passages, respectively. A manifold plate is fixed to the second plate and defines a second protruding manifold portion that overlaps with the plurality of openings of the second plate.

Description

Cooling plate with multi-mini channels

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority to U.S. patent application Ser. No. 18 / 790,629, filed July 31, 2024, the entire contents of which are incorporated herein by reference.

[0003] The present invention relates to a cooling plate having multi mini-channels and a related system.

[0004] This section provides background information related to the present invention, but is not necessarily prior art. The demand for electric vehicles and other electrical applications has significantly expanded the need for battery packs for energy storage. A battery pack may include a plurality of battery cells, or a battery module, which may include one or more battery cells. During charging and discharging of the battery pack, the battery cells may release heat. Therefore, it is desirable to provide a battery pack having a thermal management system that supports the battery cells and / or modules and may include a liquid-cooled cooling plate. The cooling plate has a coolant flow pattern that directs a liquid coolant throughout the cooling plate.

[0005] Most current cooling plate flow patterns struggle to satisfy both critical requirements: temperature balance and pressure drop. Temperature balance requires the cooling plate to provide uniform cooling across all battery cells or modules. Achieving temperature balance requires a very long and tortuous flow pattern, ensuring that the average temperature between the inlet and outlet temperatures is similar across all parts of the cooling plate. Pressure drop across a cooling plate is the amount by which pressure varies from the inlet to the outlet of the cooling plate. Because the complexity of the coolant flow path is sacrificed to achieve a low pressure drop, the temperature gaps at different locations along the cooling plate typically become larger between modules.

[0006] The problem to be solved by the present invention is to provide a cooling plate and related system having multi-mini channels.

[0007] This section provides a general overview of the present invention and is not intended to be a comprehensive description of its full scope or all features. Each embodiment disclosed herein may include one or more of the features described in connection with any other disclosed embodiment.

[0008] According to one aspect of the present invention, a cooling plate assembly comprises a first plate having a first protruding manifold portion and a plurality of protruding cooling fluid passages, each of the protruding cooling fluid passages including a first elongated portion extending parallel to the first protruding manifold portion and extending directly from the first protruding manifold portion to a U-turn bend region, the U-turn bend region connecting a second elongated portion to the first elongated portion, the second elongated portion extending parallel to the first elongated portion with a land region therebetween, the second elongated portion including a terminal portion having a land region between the terminal portion and the first protruding manifold portion, all but one of the second elongated portions being directly adjacent to two opposite first elongated portions; a second plate attached to an outer periphery of the first plate and the land of the first plate, the second plate including a plurality of through openings overlapping the terminal portion of each of the plurality of protruding cooling fluid passages; And a manifold plate fixed to the second plate and defining a second protruding manifold portion overlapping a plurality of openings of the second plate.

[0009] According to a further aspect, the manifold plate includes an outlet communicating with the second protruding manifold portion.

[0010] In a further aspect, the manifold plate includes an inlet communicating with the first protruding manifold portion through an opening in the second plate.

[0011] In a further aspect, the second protruding manifold portion is tapered to have a wider leading end that narrows toward the other end.

[0012] According to a further aspect, the manifold plate includes an inlet communicating with the second protruding manifold portion.

[0013] In a further aspect, the manifold plate includes an outlet communicating with the first protruding manifold portion through an opening in the second plate.

[0014] In a further aspect, the first plate has a substantially planar peripheral region connected to the first side of the second plate.

[0015] In a further aspect, the manifold plate has a substantially planar peripheral region connected to the second side of the second plate.

[0016] In a further embodiment, a thermal interface material is disposed on the second plate.

[0017] In a further aspect, a plurality of battery cells are supported on the thermal interface material.

[0018] In another aspect, a battery pack comprises a cooling plate assembly, the cooling plate assembly comprising a first plate having a first protruding manifold portion and a plurality of protruding cooling fluid passages, each of the protruding cooling fluid passages including a first elongated portion extending parallel to the first protruding manifold portion and extending directly from the first protruding manifold portion to a U-turn bend region, the U-turn bend region connecting a second elongated portion to the first elongated portion. The second elongated portion extends parallel to the first elongated portion with a land region therebetween, the second elongated portion including an end portion having a land region between the end portion and the protruding manifold portion, all but one of the second elongated portions being directly adjacent to two opposite first elongated portions. The second plate is attached to an outer periphery of the first plate and the land of the first plate. The second plate includes a plurality of through openings, each of which overlaps an end portion of one of the plurality of protruding cooling fluid passages. A manifold plate is fixed to the second plate and defines a second protruding manifold portion that overlaps a plurality of openings of the second plate. A plurality of battery modules are supported on the cooling plate assembly.

[0019] The present invention provides a cooling plate design that achieves a low pressure drop while maintaining a temperature balance across the entire cooling plate. Next, the cooling plate helps maintain a temperature balance between objects in contact with the cooling plate, such as battery modules. The cooling plate has multiple mini-flow patterns within a single cooling plate to maintain an average temperature similar to that of the main inlet channel, and the outlet end of the channel is provided with a hole connected to another outlet plate.

[0020] The cooling plate comprises three layers of plates, including a first plate having a plurality of mini-channels, a second plate attached to a thermal interface material, and a third exhaust channel plate.

[0021] Additional scope of application will become apparent from the description provided herein. The description and specific examples in this overview are for illustrative purposes only and are not intended to limit the scope of the present invention.

[0022] The drawings described herein illustrate only selected embodiments, do not represent all possible implementations, and are not intended to limit the scope of the invention.

[0023] FIG. 1 is a perspective view of a battery cooling system having a cooling plate assembly having multiple battery modules.

[0024] Figure 2 is an exploded perspective view of a cooling plate assembly according to the principle of the present invention.

[0025] Figure 3 is a bottom perspective view of a cooling plate assembly according to the principle of the present invention.

[0026] Figure 4 is a top perspective view of a cooling plate assembly according to the principle of the present invention.

[0027] Figure 5 is a plan view of the lower plate of the cooling plate assembly according to the principle of the present invention.

[0028] Figure 6 is a plan view of an outlet manifold plate according to the principle of the present invention.

[0029] Figure 7 is a cross-sectional view of a portion of the cooling plate taken along line 7-7 of Figure 3.

[0030] Corresponding reference numerals throughout the various drawings indicate corresponding parts.

[0031] Hereinafter, exemplary embodiments will be described in more detail with reference to the accompanying drawings. Throughout the drawings, the same or similar reference numerals are used to designate the same or similar parts, whenever possible. Embodiments of the present invention may address one or more limitations in the art. However, the scope of the present invention is defined by the appended claims, not by its ability to solve a specific problem.

[0032] The exemplary embodiments are provided so that the present invention may be thoroughly described and the scope thereof will be fully conveyed to those skilled in the art. Numerous specific details, such as specific components, devices, and methods, are described to facilitate a thorough understanding of the embodiments of the present invention. It will be apparent to those skilled in the art that the specific details are not necessarily employed, that the exemplary embodiments may be implemented in various forms, and that nothing should be construed as limiting the scope of the present invention. In some exemplary embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0033] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural as well, unless the context clearly dictates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and thus specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not to be construed as requiring that they be performed in the particular order described or illustrated, unless such order is specifically indicated. It is to be understood that additional or alternative steps may be employed.

[0034] When an element or layer is referred to as being “overlying,” “interlocked,” “connected,” or “joined” to another element or layer, it may be directly overlying, interlocked, connected, or joined to the other element or layer, and there may be no intervening elements or layers present. In contrast, when an element is referred to as being “directly overlying,” “directly interlocked,” “directly connected,” or “directly coupled” to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements (e.g., “between” and “directly between,” “adjacent” and “directly adjacent”) should be interpreted similarly. The term “and / or” as used herein includes any and all combinations of one or more of the relevant listed items.

[0035] Although terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections are not limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another. The terms “first,” “second,” etc., and other numerical terms used herein do not imply a sequence or order unless the context clearly indicates otherwise. Accordingly, a first element, component, region, layer, or section described below may also be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0036] For ease of explanation, the present specification may use spatially relative terms such as “inside,” “outside,” “below,” “lower,” “above,” and “upper” to facilitate describing the relationship of one element or feature shown in the drawings to another element(s) or feature(s). Spatially relative terms may be intended to encompass various orientations of the device in use or operation, in addition to the orientations depicted in the drawings. For example, if the device in the drawings were turned over, elements described as “below” or “below” other elements or features would be positioned “above” the other elements or features. Thus, the exemplary term “below” may encompass both the above and below orientations. The orientation of the device may be in other orientations (rotated 90 degrees or otherwise), and the spatially relative descriptors used herein are to be interpreted accordingly.

[0037] In the present invention, relative terms such as, for example, “about,” “substantially,” “typically,” “approximately,” etc., are used to indicate a possible variation of ±10% of a specified value or characteristic.

[0038] Referring to FIG. 1, a battery pack (6) is illustrated as including a cooling plate assembly (10) having a plurality of battery modules or battery cells (indicated by reference numeral (12)) arranged on a cooling plate assembly (10) within the battery pack (6). The battery pack (6) may include a sidewall structure (8) that is coupled with the cooling plate assembly (10) to form a housing. One or more cooling plate assemblies (10) may be used in the battery pack (6). The number of battery cells or modules (12) may vary depending on the application. When a battery module (12) is used, the battery module (12) may include one or more battery cells, for example, cylindrical cells, pouch cells, prismatic cells, and other known battery cell types. Moreover, in some other embodiments, individual battery cells (12) may not be housed within any module but may be in direct contact with the cooling plate assembly (10). The individual battery cells (12) may include cylindrical cells, pouch-shaped cells, prismatic cells, and any other known battery cell type. The cooling plate assembly (10) includes a lower plate (16), an upper plate (18), and a manifold plate (20), which will be described in more detail later. The cooling plate assembly (10) further includes an inlet (40) and an outlet (36) connected to the manifold plate to provide a fluid inlet and outlet for a coolant flow path within the cooling plate assembly (10), which will be described in more detail later.

[0039] The cooling plate assembly (10) may optionally be covered with a thermal interface material (14) that can be disposed between the cooling plate assembly (10) and the battery module (12) to increase heat transfer between the battery module or cell (12) and the cooling plate assembly (10). Thermal interface materials (14) are generally known in the art to enhance thermal conduction between the battery module / cell and the cooling plate assembly (10). The thermal interface material (14) may include a ceramic-filled polymer matrix (e.g., alumina-filled silicone) and is typically a compressible, compliant gap pad that reduces the air gap between the battery module or cell (12) and improves their surface contact. The thermal interface material (14) ensures efficient heat dissipation from the battery module or cell (12) to the cooling plate assembly (10) by reducing the air gap and providing greater surface contact, thereby maintaining constant cell temperatures and preventing overheating. The thermal interface material (14) may optionally be bonded to the cooling plate assembly (10).

[0040] Referring to FIG. 2, an exploded perspective view of a cooling plate assembly (10) is shown, which includes a lower plate (16) and an upper plate (18) secured to the upper portion of the lower plate (16). A manifold plate (20) is secured to the upper portion of the upper plate (18). Each of the lower plate (16), the upper plate (18), and the manifold plate (20) may be fabricated from sheet metal including aluminum, steel, or other thermally conductive metal. The connection between the lower plate (16), the upper plate (18), and the manifold plate (20) may be made by welding, soldering, clamping, adhesive, or other known connection methods.

[0041] Referring to FIGS. 3 and 5, a lower plate (16) is illustrated, which includes a peripheral region (22) that may be flat or approximately planar. A longitudinal inlet manifold portion (24) may be stamped or otherwise formed into the lower plate (16) so as to protrude away from the plane of the peripheral region (22). The manifold portion (24) may extend partially across a majority of the width of the lower plate (16). As best shown in the cross-sectional view of FIG. 7, the manifold portion (24) may include a side wall (24a) and a top wall (24b). The side wall (24a) extends from the peripheral region (22) and is connected to the top wall (24), as best shown in the cross-sectional view of FIG. 7. The top wall portion (24b) may be approximately planar and may lie within a plane that is approximately parallel to the peripheral region (22).

[0042] With continued reference to FIGS. 3 and 5, a plurality of cooling fluid passages (26) are also stamped or otherwise formed into the lower plate (16) so as to protrude from the plane of the outer peripheral region (22) in the same direction and manner as the manifold portion (24). The cooling fluid passages (26) each have a first elongated portion (26a) extending directly from the inlet manifold portion (24), such that each first elongated portion (26a) is in fluid communication with the elongated inlet manifold portion (24). The protruding cooling fluid passages (26) further include a U-turn bend portion (26b) connecting a second elongated return portion (26c) to the first elongated portion (26a). The second elongated return portion (26c) may be parallel to the first elongated return portion (26a). As best illustrated in FIG. 5, the protruding cooling fluid passages (26) are each separated and surrounded by a land portion (28) that is flush with the outer periphery region (22). The land portion (28) extends between the first elongated portion (26a) and the second elongated return portion (26b). The plurality of protruding cooling fluid passages (26) are arranged adjacent to each other and parallel along the width of the lower plate (16). The plurality of protruding cooling fluid passages (26) extend parallel to each other and in the longitudinal direction of the lower plate (16) from the inlet manifold portion (24) to the U-turn bend portion (26b). The second elongated return portion (26c) extends from the U-turn bend portion (26b) and has an end portion (26d) that stops short of the inlet manifold portion (24) with the land (28) interposed therebetween. The cooling fluid passage (26) is arranged so that all but one of the second elongated return sections (26c) are directly adjacent to the two first elongated sections (26a) on the opposite side, and likewise, all but one of the first elongated sections (26a) are directly adjacent to the two second elongated return sections (26c) on the opposite side.

[0043] In the illustrated embodiment, nine cooling fluid passages (26) are shown. However, it should be understood that more or fewer cooling fluid passages (26) may be used depending on the size of the cooling plate assembly (10) and the cooling requirements of the battery pack (6). The length of the cooling fluid passages (26) varies depending on the size of the cooling plate assembly while providing a peripheral area (22) large enough to connect to the top plate (18). The cooling fluid passages (26) may have a width of 8 mm to 15 mm.

[0044] Referring to FIG. 4, a perspective view of a cooling plate assembly (10) is illustrated, which includes a generally flat upper plate (18) having substantially the same size and shape as a lower plate (16). As shown in FIG. 2, the upper plate (18) includes a plurality of openings (30) each aligned with and in fluid communication with a corresponding end portion (26d) of an elongated return portion (26c) of a plurality of protruding cooling fluid passages (26). The upper plate (18) engages the planar outer periphery (22) and the intermediate land (28) of the lower plate (16), such that the upper plate (18) seals and closes the protruding cooling fluid passages (26), independent of the openings (30). As best illustrated in the cross-sectional view of FIG. 7, a plurality of openings (30) in the upper plate (18) allow the fluid passages of the protruding cooling fluid passages (26) to extend from the end portion (26d) and continue through the upper plate (18).

[0045] With continued reference to FIG. 7, a manifold plate (20) is secured to the upper plate (18) and defines an outlet manifold disposed therebetween. With reference to FIG. 6, the manifold plate (20) includes a protruding manifold portion (32) extending from a generally planar outer periphery (34). The protruding manifold portion (32) covers all of the openings (30) of the upper plate (18), and the generally planar outer periphery is sealingly connected to the upper plate (18). The manifold plate (20) includes an outlet (36) communicating with the protruding manifold portion (32). The protruding manifold portion (32) is tapered to have a wider first end (32a) that narrows toward the other end. The manifold plate (20) may also include an inlet (40) in fluid communication with the opening (42) of the upper plate (18) to enter the inlet manifold section (24) of the lower plate (16). Alternatively, the inlet (40) may be directly secured to the lower plate (16) or the upper plate (18).

[0046] During operation, cooling fluid is supplied from the heat exchanger to the inlet (40). The fluid then flows through the inlet manifold section (24) into each of the plurality of parallel cooling fluid passages (26) and passes through the opening (30) of the upper plate (18). From the opening (30) of the upper plate, the fluid flows into the protruding manifold section (32) of the manifold plate (20) and is discharged through the outlet (36).

[0047] According to the cooling plate design of the present invention, the pressure difference before and after the cooling plate assembly (10) is maintained low because the cooling fluid flows in parallel through the plurality of cooling fluid passages (26). As the fluid passes through the plurality of cooling fluid passages, heat is transferred to the cooling fluid. Therefore, the temperature of the cooling fluid in the first elongated portion (26a) is lower than the temperature of the cooling fluid in the second elongated return portion (26c). However, because the first elongated portions (26a) are alternately arranged between the corresponding adjacent second elongated return portions (26c), the heat transfer from the entire cooling plate assembly (10) is more evenly distributed, and the temperature difference (i.e., the temperature change across the cooling plate assembly (10)) is reduced. The direction of the refrigerant flow through the cooling plate assembly can be reversed without change, with the manifold plate (20) defining the inlet manifold and the lower plate (16) defining the outlet manifold.

[0048] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or limiting of the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically illustrated or described. This embodiment can also be modified in various ways. Such modifications are not to be construed as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.

Claims

1. As a cooling plate assembly, A first plate having a first protruding manifold portion and a plurality of protruding cooling fluid passages, wherein the protruding cooling fluid passages each include a first elongated portion extending parallel to the first protruding manifold portion and extending directly from the first protruding manifold portion to a U-turn bend region, the U-turn bend region connecting a second elongated portion to the first elongated portion, the second elongated portion extending parallel to the first elongated portion with a land region therebetween, the second elongated portion including an end portion having a land region between the end portion and the first protruding manifold portion, the second elongated portions being all but one directly adjacent to two first elongated portions on opposite sides; A second plate attached to the outer periphery of the first plate and the land of the first plate, the second plate including a plurality of through openings each overlapping an end portion of one of the plurality of protruding cooling fluid passages; and A manifold plate fixed to the second plate and defining a second protruding manifold portion overlapping a plurality of openings of the second plate; A cooling plate assembly including:

2. In paragraph 1, A cooling plate assembly, wherein the manifold plate includes an outlet communicating with the second protruding manifold portion.

3. In paragraph 2, A cooling plate assembly, wherein the manifold plate includes an inlet communicating with the first protruding manifold portion through an opening in the second plate.

4. In paragraph 2, A cooling plate assembly wherein the second protruding manifold portion is tapered to have a wider tip portion that narrows toward the other end.

5. In paragraph 1, A cooling plate assembly, wherein the manifold plate includes an inlet port communicating with the second protruding manifold portion.

6. In paragraph 5, A cooling plate assembly, wherein the manifold plate includes an outlet communicating with the first protruding manifold portion through an opening in the second plate.

7. In paragraph 1, A cooling plate assembly, wherein the first plate has a flat outer peripheral area connected to the first side of the second plate.

8. In paragraph 7, A cooling plate assembly, wherein the manifold plate has a substantially planar outer periphery area connected to the second side of the second plate.

9. In paragraph 1, A cooling plate assembly further comprising a thermal interface material disposed on the second plate.

10. In paragraph 9, A cooling plate assembly further comprising a plurality of battery cells supported on the thermal interface material.

11. A battery pack including a cooling plate assembly, The above cooling plate assembly: A first plate having a first protruding manifold portion and a plurality of protruding cooling fluid passages, wherein the protruding cooling fluid passages each include a first elongated portion extending parallel from the first protruding manifold portion and extending directly from the first protruding manifold portion to a U-turn bend region, the U-turn bend region connecting a second elongated portion to the first elongated portion, the second elongated portion extending parallel to the first elongated portion with a land region therebetween, the second elongated portion including an end portion having a land region between the end portion and the first protruding manifold portion; A second plate attached to the outer periphery of the first plate and the land of the first plate, the second plate including a plurality of through openings each overlapping an end portion of one of the plurality of protruding cooling fluid passages, wherein all but one of the second elongated portions are directly adjacent to two of the first elongated portions on the opposite side; A manifold plate fixed to the second plate and defining a second protruding manifold portion overlapping a plurality of openings of the second plate; and A plurality of battery cells supported on the cooling plate assembly; A battery pack comprising:

12. In paragraph 11, A battery pack, wherein the manifold plate includes an outlet communicating with the second protruding manifold portion.

13. In paragraph 1, A battery pack, wherein the manifold plate includes an inlet communicating with the first protruding manifold portion through an opening in the second plate.

14. In paragraph 12, The battery pack, wherein the second protruding manifold portion is tapered to have a wider tip portion that narrows toward the other end.

15. In paragraph 11, A battery pack, wherein the manifold plate includes an inlet port communicating with the second protruding manifold portion.

16. In paragraph 15, A battery pack, wherein the manifold plate includes an outlet communicating with the first protruding manifold portion through an opening in the second plate.

17. In paragraph 11, A battery pack, wherein the first plate has a substantially planar outer periphery area connected to the first side of the second plate.

18. In paragraph 17, A battery pack, wherein the manifold plate has a substantially planar outer periphery area connected to the second side of the second plate.

19. In paragraph 11, A battery pack further comprising a thermal interface material disposed on the second plate and in contact with the plurality of battery cells.

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