Abstract:
Exemplary embodiments include method of sealing battery cooling plates, and methods of assembling battery using battery cooling plate racks and a single component including multiple cooling plates and connection portions therebetween.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/043,614 filed Apr. 9, 2008. 
    
    
     TECHNICAL FIELD 
     The field to which the disclosure generally relates includes batteries and components thereof, and methods of making and assembling the same, and in particular to battery cooling plates or fins. 
     BACKGROUND 
     For the efficient operation of some batteries, for example lithium ion batteries, it may be desirable to cool the battery. This may be accomplished by flowing a liquid coolant through a cooling plate or fin, which may be positioned adjacent to a battery cell or interposed between battery cells. As the commercial use of such battery increases, effective methods of making components thereof and manufacturing assembly operations become more important. 
     SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION 
     One exemplary embodiment includes a method of assembling battery cooling plates which are connected together in a rack form with a space provided between cooling plates sufficient to receive two battery cells. A spring element is sandwiched between two battery cells to provide a battery pack subassembly that is compressed so that the thickness of the battery pack subassembly in the compressed state is less than the distance between two adjacent cooling plates in the rack. The battery pack subassembly is then slid between two adjacent cooling plates once the battery pack subassembly is positioned between two adjacent cooling plates in the rack, the spring element expands to press the first battery cell against the first cooling plate and the second battery cell against the second cooling plate. 
     Another exemplary embodiment includes a method including providing a single substrate having a plurality of spaced-apart battery cooling plates defined therein. A battery cell may be attached to one or both sides of each cooling plate. The substrate includes a connection portion joining adjacent cooling plates and the connection portion includes at least one cooling channel communicating with each of the adjacent cooling plates. The arrangement provides multiple cooling plates formed as one component in series. The substrate may be bent at the connection portion so that adjacent cooling plates and the batteries attached thereto may be provided in an overlying position with respect to each other. 
     Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the invention will become more fully understood from the following detailed description and the accompanying drawings. 
         FIG. 1  illustrates a method of assembling a battery using a cooling plate rack and a battery pack subassembly according to one exemplary embodiment. 
         FIG. 2  is an exploded view of a battery pack subassembly and associated holders according to one exemplary embodiment. 
         FIG. 3  is an illustration of a holder-battery pack subassembly in a compressed state according to one exemplary embodiment. 
         FIG. 4  illustrates a method of assembling a battery according to one exemplary embodiment. 
         FIG. 5A  illustrates a method of assembling a battery according to one exemplary embodiment. 
         FIG. 5B  illustrates a method of assembling a battery according to one exemplary embodiment. 
         FIG. 5C  illustrates a method of assembling a battery according to one exemplary embodiment. 
         FIG. 5D  illustrates a method of assembling a battery according to one exemplary embodiment. 
         FIG. 6  illustrates a method of assembling a portion of a battery according to one exemplary embodiment. 
         FIG. 7  illustrates a method of assembling a portion of a battery according to one exemplary embodiment. 
         FIG. 8  illustrates a method of assembling a battery according to one exemplary embodiment. 
         FIG. 9  illustrates a method of assembling a battery according to one exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The following description of the embodiment(s) is merely exemplary (illustrative) in nature and is in no way intended to limit the invention, its application, or uses. 
     Referring now to  FIGS. 1-5 , one exemplary embodiment includes a method of making a battery assembly including a plurality of battery cells and cooling plates. As shown in  FIG. 1 , in one illustrative embodiment a radiator assembly  200  may be provided including a plurality of cooling plates  202  having cooling fluid flow paths defined therein and a first series of components  204  to provide a first manifold portion and a second series of components  206  to provide a second manifold for flowing cooling fluid from one cooling plate to the next cooling plate in series. A space  224  may be provided between the adjacent main body portions of cooling plates  202  into which a battery pack subassembly  208  may be inserted. 
     Referring now to  FIG. 2 , in one exemplary embodiment, the battery pack subassembly  208  may include a first battery cell  210  and a second battery cell  212 . A spring element  214  may be interposed between the first battery cell  210  and the second battery cell  212 . In one embodiment, the spring element  214  may be one or more wave-shaped substrates for applying a biasing force against each of the first battery cell  210  and second battery cell  212 . In other embodiments the spring  214  may be a resilient foam, a rubber or elastomeric material. Each of the first battery cell  210  and second battery cell  212  may include a first terminal  218  and second terminal  220 . The first battery cell  210 , spring element  214  and second battery cell  212  may be held together in a compressed state by one or more holders  216 . In one embodiment multiple holders  216  may be used. In one embodiment the battery pack subassembly  208  and holder  216  may be held together by a hydraulic clamp.  FIG. 3  illustrates an exemplary embodiment of a holder-battery pack subassembly wherein the first battery cell  210 , spring element  214  and second battery cell  212  are held together in a compressed state. 
     Referring now to  FIG. 4 , in one exemplary embodiment, the holder-battery pack subassembly  222  may be utilized to insert the battery pack subassembly  208  into the space  224  provided between the main body portions of adjacent cooling plates  202 . In one exemplary embodiment, the holder-battery pack subassembly  222  may be placed over adjacent cooling plates  202  so that the holders  216  at least partially rest on a portion of the adjacent cooling plates  202 . The holder-battery pack subassembly  222  may be positioned so that the battery pack subassembly  208  is aligned with the space  224  and the battery pack subassembly  208  may be pushed downward into the space  224  so that the battery pack subassembly  208  is completely received and the space  224  and the spring element  214  forces the first battery cell against a first cooling plate and so that the spring element  214  faces the second battery cell  212  against a second adjacent cooling plate  202  to enhance the heat transfer between the battery cells  210 ,  212  in the cooling plates  204 . 
     Referring now to  FIG. 5A , an electric, pneumatic or hydraulic assembly jig clamp may close the holders  216  around the battery pack  208  including the first and second battery cells  210 ,  212  with the spring therebetween. The assembly jig compresses the battery pack  208  ( FIG. 5B  and then is used to insert the battery pack  208  between two cooling plates  202  of the rack ( FIG. 5C ). Once the battery pack  208  has been inserted into the rack the assembly jig opens so that the holders  216  release their grip on the battery pack  208 . 
     Referring now to  FIGS. 6-9 , another exemplary embodiment includes a method of manufacturing a battery assembly including a continuous component  300  including multiple cooling plates formed in series. The continuous component  300  may include a first substrate  302 , which may define at least in part a plurality of cooling plates and connection portions extending therebetween. A second substrate (not shown) may be stamped or otherwise formed to define a pattern of lands and channels. The first substrate  302  may cover the lands and channels. For example, the first substrate  302  may define at least a portion of a first cooling plate  304 , a first connection portion  306  extending therefrom and connecting to a second cooling plate  308 , a second connection portion  310  extending therefrom and connecting to a third cooling plate  312 , and a third connection portion  314  extending therefrom and connecting to a fourth cooling plate  316  and a fourth connection portion  318  extending therefrom. The pattern of a first cooling plate, a connection portion extending therefrom and connecting to a second cooling plate may be repeated numerous times depending upon the size of the battery assembly to be manufactured. The connection portions  306 ,  310 ,  314 ,  318  may be of varying sizes and may be positioned at various locations. In one exemplary embodiment, the first connection portion  306 , second connection portion  310 , third connection portion  314  and fourth connection portion  318  may be provided by forming a first window  320 , a second window  322 , a third window  324  and a fourth window  326  in the substrate  302  so that the connection portions  306 ,  310 ,  314  and  318  have a height substantially less than the cooling plates  304 ,  308 ,  312 ,  316  and so that the connection portions may easily be bent 180°. At least one cooling path  328  is provided through the cooling plates  304 ,  308 ,  312 ,  316  and connection portions  306 ,  310 ,  314  and  318 . A first battery cell  330  may be positioned over a first face  332  of a cooling plate  304 . In one embodiment, the first battery cell  330  is attached to the first face  332 , for example by using a thermally conductive adhesive. In another embodiment, the battery cell  330  may be sandwiched in position when the substrate  302  is bent. If desired, a second battery  334  may be positioned over a second face  336  of a cooling plate  304 . Battery cells may be attached to or positioned adjacent the first face  332  and/or the second face  336  of each of the cooling plates. 
     In an embodiment where battery cells are attached to each of the first face  332  and the second face  336  of each cooling plate, the connection portions may be bent 180° so that the battery cell attached to the first face  332  of adjacent cooling plates are positioned immediately adjacent to each other. For example, a battery cell  330  may be attached to each of the first faces  332  of the first cooling plate  304  and another battery cell  330  may be attached to a second cooling plate  308 , the first connection portion  306  may be bent in a manner which avoids blocking the cooling passage  328  extending through the first connection portion  306  so that the first battery cells  330  are immediately adjacent to each other. Thereafter, the second connection portion  310  may be bent in the opposite direction so that the second battery cell  330  on each of the second face  336  of the second cooling plate  308  and the third cooling plate  312  are immediately adjacent each other. This method of bending the connection portions may be repeated until a battery of sufficient size has been formed. 
       FIG. 8  illustrates another exemplary embodiment include a method of making a battery using a continuous component  300  having a cooling fluid flow path  328  defined therein wherein the continuous component  300  may be bent at locations A and B and utilized to make a battery in a manner similar to that as described for  FIGS. 6-7 . 
       FIG. 9  illustrates another exemplary embodiment include a method of making a battery using a continuous component  300  having a cooling fluid flow paths  328  therein to define a plurality of cooling plate sections (individually defined by lines C, D and E). A cooling fluid inlet manifold flow path  900  and an outlet manifold flow path may each be provided communicating with each of the cooling plate sections C, D and E. The continuous component  300  may be bent generally at the intersection of lines C-D and D-E and utilized to make a battery in a manner similar to that as described for  FIGS. 6-7 . 
     The above description of embodiments of the invention is merely exemplary in nature and, thus, variations thereof are not to be regarded as a departure from the spirit and scope of the invention.