Patent Description:
Battery packs used within high end clusters, such as electric vehicle battery packs, require advanced thermal management to combat challenges associated with non-uniform temperature profiles or operating temperatures that are too high or too low. Such problems can cause issues such as reduced lifetime of the battery pack, battery fade, and reduced discharge current / operational time. These challenges are amplified within high-discharge rate and varying transient discharge applications, such as motorsport electric vehicle applications. Ambient temperatures also affect the performance of the battery pack. To maximize the electrical performance and lifetime of a battery pack, it is sometimes required to maintain an isothermal temperature across the surface of each cell, across all cells within the pack, or to cool or heat the entire pack to maintain the isothermal temperature within a specific temperature range.

Current formula-E battery packs use individually formed microchannel cold flow plates that are connected to a relatively bulky polymer chassis. The polymer component incorporates through-holes and o-rings that when stacked next to one another are compressed to form a seal between adjacent cold plates and the polymer frames. By stacking multiple frames / pouch cells, inlet and outlet plenums are formed enabling a single liquid inlet and outlet port to be deployed. A major issue with these current systems, however, is that there are hundreds of seals in the battery pack (<NUM> per pouch cell) that are prone to leaking. Additionally, these types of devices have a relatively large mass due to the bulky polymer chassis. <CIT> discloses a heat exchanger for temperature control of electronic components or electrical energy stores. The heat exchanger includes a cooling plate with fluid channels that extend along the cooling plate. The cooling plate has openings at opposite ends as ends of the fluid channels. Further, the heat exchanger includes a collector being provided at the opposite ends of the cooling plate, with the fluid channels being fluidly connected. The cooling plate is joined to the collectors such that the fluid channel are connected in a fluid-tight manner. <CIT> discloses a lithium ion battery pack including a plurality of prismatic lithium polymer cells and one or more graphite heat spreaders. Each spreader has at least two major surfaces and is made of one of a sheet of a compressed mass of exfoliated graphite particles, a graphitized polyimide sheet, or combinations thereof. <CIT> discloses a battery module and a method for cooling the battery module. The battery module includes a first battery cell and a cooling fin disposed adjacent to the first battery cell. The cooling fin has first and second headers, an extruded housing, and a flow diverter. The first and second headers are coupled to first and second ends, respectively, of the extruded housing. The extruded housing has a first plurality of flow channels and a second plurality of flow channels extending therethrough that fluidly communicate with the first and second headers. The flow diverter is disposed in the first header to induce a fluid to flow from the first header through the first plurality of flow channels in the extruded housing to the second header to extract heat energy from the first battery cell.

In one embodiment, the invention provides a device for removal of heat from a plurality of heat sources according to claim <NUM>.

Before any constructions of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other constructions and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited.

The term "thermal management system" used herein refers to any system that is arranged to remove heat from one or more heat sources and to move the heat to a separate location. The term "spreader" used herein refers for example to a plate, sheet, disk, enclosure, chamber, or other structure that receives heat and spreads or otherwise moves the heat from one location to another (e.g., linearly or generally within a plane defined by the spreader). The term "k-Core" used herein refers to Thermacore's k-Core technology (k-Core® material, available from Thermacore, Inc. of Lancaster, PA <NUM>), which uses encapsulated graphite to move heat (e.g., in avionic applications). One example of k-Core technology material is encapsulated annealed pyrolytic graphite (APG) which creates high-conductivity thermal spreading (e.g., up to three times the conductivity of solid copper with lower mass than aluminum). The term "encapsulated" or "encapsulating material" or "encapsulant" used herein refers, for example, to material (e.g., an aluminum foil, copper alloy, ceramic, composite, or other material) that forms an enclosure or covering or in some instances a chamber and that encapsulates or otherwise encloses and contains material therein, such as k-Core material.

In one exemplary embodiment, as shown in <FIG>, a thermal management system <NUM> may be used in any application where multiple heat dissipating devices, such as battery packs or other electrical components, including a closely-packed or stacked heat source, require temperature control within a specific temperature range or an isothermal temperature profile throughout the device. The present embodiment can be applied in thermal management of electric vehicle battery packs using flat or generally flat pouch cells <NUM> stacked in multiple banks of cells that are installed into an overall battery pack chassis. Each bank of pouch cells <NUM> is directly coupled to or otherwise is in communication with one or more of the thermal management systems <NUM> described herein. The term "pouch cell" used herein refers to a heat source, and in the illustrated embodiment, to a heat source having a structure that acts as a fuel cell or battery cell of a battery pack. The pouch cell <NUM> defines an enclosure or chamber therein for generation of energy. <FIG> illustrate a single pouch cell <NUM>.

Other cell formats, including, but not limited to cylindrical cells, are also envisioned. Cylindrical cells represent a common type of battery format (e.g., for an AA battery) typically for consumer use. The interior of a typical cylindrical battery includes three concentric layers of film/foil (copper, polymer isolation layer and aluminum foil) that are rolled up inside the battery cylinder and that define the current and voltage. One foil (e.g., aluminum) has a carbon coating that stores the charge. An electrolyte fills the voids between the layers. In some embodiments, rather than rolling up the adjacent foil and polymer layers into a cylinder, multiple separate sheets of foil and polymer are stacked on top of one-another. The foil layers may be vacuum sealed within a polymer film container (typically used in the food industry) that forms a flat rectangular pack. The laminated layers forming the positive and negative terminals are exposed. The rectangular shape increases packing density into the pack chassis.

In some embodiments, the thermal management system <NUM> described herein includes three main components (see <FIG>, <FIG>, and <FIG>):.

With reference to <FIG> and <FIG>, the thermal management system <NUM> includes a first thermal regulation system 26A disposed on one side of the pouch cells <NUM> (e.g., above the pouch cells <NUM>) and a second thermal regulation system 26B disposed on an opposite side of the pouch cells <NUM> (e.g., below the pouch cells <NUM>). Thermal conduction devices <NUM> extend from each of the thermal regulation systems 26A, 26B toward one another, and are disposed adjacent to the pouch cells <NUM>, including in between adjacent pouch cells <NUM>.

The thermal conduction device <NUM> may be any heat transfer device (e.g., a heat spreader) that receives heat from one or more of the pouch cells <NUM> (or other heat sources) and transfers the heat away from the pouch cell <NUM> and to one of the thermal regulation systems 26A, 26B. In the illustrated embodiment, each thermal conduction device <NUM> includes a flat or generally flat conduction plate <NUM> (e.g., a flexible sheet) made of graphite (e.g., encapsulated graphite). The conduction device <NUM> contacts a surface <NUM> (<FIG>) of the pouch cell <NUM> or is otherwise closely positioned or spaced relative to the surface <NUM> of the pouch cell <NUM> for thermal communication with the pouch cell <NUM>. In some embodiments, the thermal conduction device <NUM> may be positioned proximate the surface <NUM> of the pouch cell <NUM> such that there is a gap between the thermal conduction device <NUM> and the pouch cell <NUM>. In this configuration, the thermal conduction device <NUM> still receives heat from the pouch cell <NUM> even though the thermal conduction device <NUM> is spaced from the pouch cell <NUM>.

The thermal conduction plate <NUM> has relatively high thermal conductivity to produce uniform heat distribution across the surfaces of the pouch cell <NUM>, smoothing out hot spots and creating a more isothermal temperature profile across the surface <NUM> of the pouch cell <NUM>. In some embodiments, and as described further herein, an edge of the plate <NUM> extends past the pouch cell surface <NUM> and thermally interfaces with a secondary heat extraction system (e.g., one of the thermal regulation systems 26A, 26B). The secondary heat extraction systems extract heat from the thermal conduction device <NUM> (e.g., from the plate <NUM>) to control and to maintain the pouch cell <NUM> within a required operating temperature range. High thermal conductivity materials other than graphite, including but not limited to aluminum and copper, may be used in alternative embodiments of the thermal conduction device <NUM>.

One feature of the illustrated thermal conduction device <NUM> is the use of an encapsulated graphite material for heat transfer. For example, a graphite material core with very high in-plane thermal conductivity in comparison to copper and aluminum, may be protected (e.g., encapsulated) within a protective skin (metal foil, polymer, composite sheet, carbon fiber etc.) to provide good thermal transfer capability. The very high in-plane thermal conductivity of the graphite core minimizes the thermal gradient between the high temperature regions of the pouch cell <NUM> and the interface with the thermal regulation system 26A, 26B, resulting in a lower operating temperature and a temperature profile across the pouch cell surface <NUM> that is close to or approaching isothermal conditions.

With continued reference to <FIG> and <FIG>, the use of the conduction plate <NUM> as a graphite spreader may provide further increased flexibility in comparison to solid metal plates. This flexibility accommodates expansion and contraction of the pouch cell <NUM> caused by expansion and contraction of the electrolyte solution contained within the pouch cell <NUM> in response to changes in temperature. To benefit from the increased flexibility of the graphite-based conduction plate <NUM>, and as illustrated in <FIG>, a configuration of the thermal conduction device <NUM> may incorporate separate conduction plates <NUM> that are connected independently to the upper and lower thermal regulation systems 26A, 26B, respectively. The upper and lower thermal regulation systems 26A, 26B are fixed rigidly in position. By separating the thermal conduction devices <NUM>, increased flexibility is achieved.

A further embodiment of the thermal conduction device <NUM> uses graphene sheets or films as an alternative to graphite. As graphene has excellent barrier properties, there is no need to encapsulate the graphene, providing an improvement in thermal performance versus that of an encapsulated graphite device. In addition, the 2D-like configuration or flat nature of the graphene sheets has a very small thickness and gives a very high level of flexibility.

In some embodiments the grains of the graphene or graphite flakes are all aligned along a common direction in a plane of the thermal conducting device, such that heat is directed in the common direction.

It should be noted that the surface of the graphene may be functionalized, potentially by the addition of a copper flash or polymerization. Functionalization achieves benefits such as improved through-plane thermal conductivity and increased adhesion of the individual graphene layers. Although true graphene should be one atom thick (2D), commercially available materials can be manufactured from using flakes with up to <NUM> layers. The surface of the flakes is functionalized by, for example, polymerization which helps protect the graphene and helps the flakes adhere to one another during consolidation. Copper flash does the same but has a higher thermal conductivity and is more difficult to consolidate into bulk material.

In a further embodiment of the thermal management system <NUM>, the pouch cell <NUM> directly incorporates the thermal conduction device <NUM> within the pouch cell <NUM>, eliminating or reducing thermal resistance between the thermal conduction device <NUM> and the pouch cell surface <NUM> in the thermal path. As such, in this configuration, the heat source or pouch cell <NUM> is directly coupled to the thermal regulation system 26A, 26B. In addition, by the addition of one or more layers between the cell sheet layers, the thermal conductivity through the thickness (width) of the pouch cell <NUM> can be made isothermal (i.e., a 3D isothermal temperature profile). In a case where graphite or graphene based thermal conduction materials are used, the material may replace the existing graphitic layer and perform both the electrical and thermal functions within the pouch cell <NUM>.

With reference to the exemplary embodiment of <FIG>, each of the thermal regulation systems 26A, 26B is formed in the nature of a framework of manifolds (i.e., frame members), including pipes, tubes, etc. that are coupled to one or more of the thermal conduction devices <NUM>. In the illustrated embodiment, as shown in <FIG>, each thermal regulation systems 26A, 26B includes a first frame member <NUM> having an inlet <NUM> to receive a working fluid A (e.g., coolant / refrigerant / two-phase flow, as illustrated in <FIG>). Each of the thermal regulation systems 26A, 26B also includes a second frame member <NUM> that is spaced from the first frame member <NUM>. In the illustrated embodiment, the second frame member <NUM> extends parallel to the first frame member <NUM>. The second frame member <NUM> includes an outlet <NUM> for the working fluid A to exit the thermal regulation system 26A, 26B. As illustrated in <FIG>, the working fluid A may enter the inlet <NUM> in one direction, and exit the outlet <NUM> in the same direction. The thermal regulation system 26A, 26B further includes a plurality of intermediate frame members <NUM> that extend between the first and second frame members <NUM>, <NUM>. For example, as shown in <FIG>, the intermediate frame members <NUM> extend perpendicularly relative to the first and second frame members <NUM>, <NUM> and parallel to one another. The thermal conduction devices <NUM> are coupled to the intermediate frame members <NUM> (e.g., see <FIG>). More specifically, the thermal conduction devices <NUM> are releasably coupled to the intermediate frame members <NUM>.

The thermal regulation systems 26A, 26B extract heat generated by the pouch cells <NUM> (or other heat sources) that has been transferred to the thermal conduction devices <NUM>, and thermally regulate the operating temperature of the overall thermal management system <NUM>. In the illustrated embodiment, and as described above, the thermal management system <NUM> includes an upper thermal regulation system 26A and a lower thermal regulation system 26B. In other embodiments, the thermal management system <NUM> may include only one thermal regulation system <NUM>, or more than two thermal regulation systems. The upper and lower thermal regulation systems 26A, 26B, as shown in <FIG>, <FIG>, are configured to form the structure of a rigid chassis <NUM>, or more particularly, a low mass rigid chassis, to which the thermal conduction devices <NUM> and/or pouch cells <NUM> are coupled. The intermediate frame members <NUM> of the chassis <NUM> incorporate fluid flow channels <NUM> (e.g., microchannels) that enable the working fluid A to pass through the chassis <NUM>. By controlling the flowrate and inlet temperature of the working fluid A, heat extraction from the thermal conduction devices <NUM> and the temperatures of the thermal conduction devices <NUM> and pouch cells <NUM> are controlled.

<FIG> illustrate one of the upper or lower thermal regulation systems 26A, 26B. The thermal regulation system 26A, 26B in the illustrated embodiment includes two elements (i.e., the first frame member <NUM> and the second frame member <NUM>) that form the outer framework of the chassis <NUM>. The first and second frame members <NUM>, <NUM> are interconnected by the intermediate frame members <NUM>. The intermediate frame members <NUM> are a series of parallel structural elements that act as struts or cross-struts. As noted above, the intermediate frame members <NUM> extend, in some embodiments, perpendicularly between the first frame member <NUM> and the second frame member <NUM> (see <FIG>).

With continued reference to <FIG>, the outer framework elements <NUM>, <NUM> (i.e., the first and second frame members) are hollow, forming large inlet and outlet conduits <NUM>, <NUM>. The conduit <NUM> of the first frame member <NUM> of the outer framework elements <NUM>, <NUM> provides an inlet manifold to supply the working fluid A through inlet ports <NUM> (<FIG>) to the intermediate frame members <NUM>. The intermediate frame members <NUM> are also hollow, but in contrast to the large conduit <NUM> of the first frame member <NUM>, each of the intermediate frame members <NUM> includes at least one microchannel <NUM>. More specifically, the microchannels <NUM> provide relatively high thermal efficiency flow passages that enhance the collection of heat from the parallel thermal conduction devices <NUM> and transfer the collected heat into the working fluid A flowing through the microchannels <NUM>. The conduit <NUM> of the second frame member <NUM> of the outer framework elements <NUM>, <NUM> acts as an outlet manifold to receive the working fluid A from the microchannels <NUM> of the intermediate frame members <NUM> through outlet ports <NUM> (<FIG>) of the second frame member <NUM>.

Each of the intermediate frame members <NUM> includes one of the microchannels <NUM> (<FIG>) to transfer working fluid A from the first frame member <NUM> to the second frame member <NUM>. In other embodiments, the intermediate frame members <NUM> may be formed with relatively larger channels. The intermediate frame members <NUM> thus are configured to conduct the working fluid A along the heated ends of the thermal conduction devices <NUM> coupled to the intermediate frame members <NUM> so that heat generated by the thermal conduction devices <NUM> is absorbed by the working fluid A as the working fluid flows through the second frame member <NUM>. The heat absorbed from the thermal conduction devices <NUM> by the working fluid A is then transferred out of each of the thermal regulation systems 26A, 26B when the working fluid A exits the outlet <NUM> of second frame member <NUM>.

With reference to <FIG>, <FIG>, in the illustrated embodiment, the intermediate frame members <NUM> are joined to the first and second frame members <NUM>, <NUM> to create an interconnected fluid flow passage network (<FIG>) in a parallel flow configuration (other configurations may be used) that balances the pressure drop and/or the flow rate through each microchannel <NUM>. This fluid flow passage network may facilitate a uniform heat transfer coefficient within each parallel microchannel <NUM>. In particular, <FIG> illustrate the inlet conduit <NUM>, the inlet ports <NUM>, and the microchannels <NUM> in fluid communication. The illustrated outlet conduit <NUM> and outlet ports <NUM> are similarly configured to interact with the microchannels <NUM> to move the working fluid A. In the illustrated embodiment, the thermal conduction devices <NUM> extend away from the framework or chassis <NUM> along a direction that is perpendicular to a direction of movement of working fluid within the framework of the thermal regulation systems 26A, 26B.

With reference to <FIG> and <FIG>, the thermal extraction interface <NUM> corresponds to the connections between the thermal conduction devices <NUM> and the thermal regulation systems 26A, 26B. In particular, it refers to the connections between ends of the thermal conductions devices <NUM> (e.g., edges of the plates <NUM>) and the intermediate frame members <NUM> (e.g., slots described below). For example, as illustrated in the embodiments of <FIG> and δ, the profile of each of the plurality of intermediate frame members <NUM> includes two main features. The first feature is a circular (or other shape) tube portion <NUM> within which the circular microchannel passage <NUM> runs along the longitudinal axis of the intermediate frame member <NUM>. As shown, The tube portions <NUM> are in fluid communication with the inlet and outlet ports <NUM>, <NUM> of the conduits <NUM>,<NUM>, respectively. The second feature is a pair of parallel spaced-apart protrusions <NUM> (e.g., fingers, elongate arms, or other extending structural features, etc.) extending outwardly from and along the length of the circular tube portions <NUM>. The protrusions <NUM> form a slot <NUM> (e.g., groove, crease, etc.) therebetween that extends along a longitudinal axis of the intermediate frame member <NUM>.

A portion of each of the thermal conduction devices <NUM> is received and held in the slot <NUM> formed by each pair of spaced-apart protrusions <NUM> to form the thermal extraction interface <NUM> between the thermal conduction device <NUM> and the tube <NUM>. In particular, heat generated by the thermal conduction devices <NUM> and received by the pair of spaced-apart parallel protrusions <NUM> is conducted through the circular tube portion <NUM> where the heat is then absorbed by the working fluid A flowing through the microchannel <NUM>. The wall thicknesses of the parallel protrusions <NUM> and the microchannel tube <NUM> may be varied to optimize heat transfer and minimize the mass of the thermal conduction devices <NUM>. For example, the height and width of the slot <NUM> may be varied to accommodate various configurations and types of the thermal conduction devices <NUM> to optimize heat transfer between the thermal conduction devices and the working fluid A flowing through the microchannels of the intermediate frame members <NUM>. An interface material such as solder or epoxy or any other suitable alternative filler material may be used to minimize thermal resistance and maximize thermal conduction across the joint between the thermal conduction devices <NUM> and the associated intermediate frame members <NUM>.

With reference to <FIG>, in the illustrated embodiment the intermediate frame members <NUM> each have a constant cross-sectional profile along the length of its entire length to enable manufacture by extrusion. Alternatively, the cross-sectional profile along the length of the intermediate frame members <NUM> may be varied by using additional or alternative manufacturing processes.

In some embodiments, a mechanical device may be used to hold the thermal conduction device <NUM> in position on the intermediate frame member <NUM>. For example, a wedge and/ or a plate may be used to clamp or otherwise secure a thermal conduction device <NUM> to an intermediate frame member. In some embodiments, the intermediate frame member <NUM> may only include one protrusion <NUM> instead of a pair of spaced-apart protrusions, and a flat plate may be used to clamp the thermal conduction device <NUM> to the protrusion <NUM>. The protrusion and separate flat plate thus act as a capture feature. The terms "capture feature" or "capture features" refer to any structural features or structures that are used to "capture" (i.e., receive, retain, hold, secure, encompass, etc.) another component, such as the thermal conduction device <NUM> or one of the first, second, or intermediate frame members <NUM>, <NUM>, <NUM>, respectively, to hold them in place.

As shown in the embodiment of <FIG>, the first and/or second frame member <NUM>, <NUM> includes capture features that are formed as recessed regions <NUM> (e.g., keyed regions) sized and shaped to receive an end of an intermediate frame member <NUM>. In the illustrated embodiment, each of the first and second frame members <NUM>, <NUM> includes multiple recesses each dimensioned to correspond to the cross-sectional profile of the intermediate frame members <NUM> (<FIG>). The recesses <NUM> of the first and second frame members <NUM>, <NUM> align the orientation of the intermediate frame members <NUM> relative to the first and second frame members <NUM>, <NUM> and the microchannels <NUM> with the inlet and outlet ports <NUM>, <NUM> provided along the lengths of the first and second frame members <NUM>, <NUM> (<FIG>). In other embodiments, the capture features may be protrusions, fingers, or any other surfaces or structures that are sized and shaped to securely hold one component in position with respect to another component.

In some embodiments, the interfaces between the intermediate frame members <NUM> and the first and second frame members <NUM>, <NUM> are sealed by brazing, welding or using an epoxy. In some embodiments, the end of the first frame member <NUM> opposite the inlet <NUM> and/or the end of the second frame member <NUM> opposite the outlet <NUM> are sealed using a cap <NUM> (<FIG>).

With reference to <FIG>, the cross-sectional profile of each of the illustrated microchannels <NUM> may be designed to minimize mass (i.e., weight) of the framework, and/or to minimize thermal resistance and improve thermal conduction. For example, the single microchannel <NUM> may be replaced with a multi-channel configuration (<FIG>) to increase heat transfer. The channel shape and size also may varied. For example, the cross-sectional profile of microchannel <NUM> may be shaped as a square, triangle or any other desired shape to provide a capillary action. Examples of such different cross-sectional profiles for microchannels <NUM> are shown in <FIG>, including multi-channel configurations. In addition, more than one thermal conduction device <NUM> may be thermally associated with each intermediate frame member <NUM>. For example, intermediate frame members <NUM> provided with more than one capture feature (e.g., two or more pairs of spaced-apart protrusions <NUM>) to hold more than one thermal conduction device <NUM> are shown in <FIG>.

In some embodiments, intermediate frame members <NUM> with two capture features (e.g., two pairs of spaced-apart parallel protrusions <NUM>) may be used, for example, to thermally manage two battery cells as shown, for example, in <FIG>. In the illustrated embodiment, the mass of the entire thermal transfer device <NUM> is reduced in that two sets of battery cells are thermally managed by three thermal regulation systems 26A, 26B, 26C instead of four systems with a separate pair of thermal regulations systems 26A, 26B for each set of battery cells. In this configuration, the intermediate frame members <NUM> of the thermal management system 26B are configured as having the cross-section profile as shown in <FIG> (the intermediate frame members <NUM> including two pairs of spaced-apart parallel protrusions <NUM>). In other embodiments, the thermal management system <NUM> may include multiple sets of battery cells such that the intermediate frame members <NUM> of the thermal management system 26B are configured as having the cross-section profiles as shown in <FIG> (the intermediate frame members <NUM> including four pairs of spaced-apart parallel protrusions 90A). A close-up view of the assembled components of the thermal management system <NUM> of <FIG>, in particular the thermal regulation system 26B, is shown in <FIG>. The overall assembly with the pouch cells <NUM> in position is also shown in <FIG>.

In some embodiments, the chassis <NUM> may be formed as a light-weight chassis framework, manufactured from brazed aluminum extrusion profiles (or material other than aluminum) to form parallel flow liquid cold plates or frame members including, for example, the intermediate frame members <NUM>. Each parallel intermediate frame member <NUM> and flow channel <NUM> connects to a k-Core foil encapsulated spreader (e.g., conduction device <NUM>) that is installed between two adjacent pouch cells <NUM>. During use, the pouch cells <NUM> (or other heat sources) generate heat. That heat is transferred to the associated or adjacent thermal conduction device(s) <NUM> (e.g., to the k-Core plates <NUM>). The thermal conduction devices <NUM> extend parallel to one another, and extend into spaces or gaps between the pouch cells <NUM> (e.g., like fingers). Thus, the thermal conduction devices <NUM> pick up the heat from the pouch cells <NUM> and move the heat away from the pouch cells <NUM> toward the thermal regulation system 26A, 26B. As illustrated in <FIG>, and as described above, a first upper thermal regulation system 26A and a second lower thermal regulation system 26B are provided. The thermal conduction devices <NUM> extend from both the first thermal regulation system 26A and the second thermal regulation system 26B (e.g., toward each other). Once the heat reaches the ends or edges of the thermal conduction devices <NUM> (which are captured or otherwise held by the protrusions <NUM> of the intermediate frame members <NUM>), the heat moves into the microchannels <NUM> in the intermediate frame members <NUM>. From there the heat is picked up by the working fluid A passing through the microchannels <NUM>, and is moved to the second frame member <NUM> and then out of the thermal management system <NUM>.

The thermal management systems <NUM> described herein may be used in electric vehicle (EV) thermal management. In particular, in some embodiments they are directed for use with Formula-E battery packs and other high performance EV applications, although they could be used on vehicles other than electric vehicles, or could be used in systems other than vehicles (e.g., in stationary systems that have heat sources, such as electronics) to remove heat. In some embodiments, the thermal management systems <NUM> described herein may be used in high performance electric vehicle battery pack applications and low volume and niche EV automotive applications (e.g. busses, excavators, tractors, trucks, etc.).

In some embodiments, the thermal management systems <NUM> include (<NUM>) use of K-Core as a thermal spreader to regulate and even out pouch cell temperature, (<NUM>) a K-Core thermal transport to a liquid cooling system and integration with the cooling system, (<NUM>) a method or arrangement of interconnections between K-Core material and a cooling system, and/or (<NUM>) a design of a liquid cooling system to be a structural chassis framework <NUM>.

Claim 1:
A device (<NUM>) for removal of heat from a plurality of heat sources, the device comprising:
a first manifold (<NUM>) configured to receive a working fluid;
a plurality of first elongated intermediate frame members (<NUM>) each in thermal communication with at least one of the plurality of heat sources, each first elongated intermediate frame member (<NUM>) including a channel (<NUM>) in fluid communication with the first manifold (<NUM>) and configured to receive the working fluid from the first manifold (<NUM>), wherein each first elongated intermediate frame member (<NUM>) includes a slot (<NUM>) defined by two spaced apart protrusions (<NUM>) extending outwardly from the first elongated intermediate frame member (<NUM>) and parallel to one another along a longitudinal axis of the first elongated intermediate frame member (<NUM>);
a second manifold (<NUM>) spaced from the first manifold (<NUM>) and in fluid communication with the plurality of first elongated intermediate frame members (<NUM>) to receive the working fluid from each channel (<NUM>) in the plurality of first elongated intermediate frame members (<NUM>), wherein the second manifold (<NUM>) is configured to transfer the working fluid away from the plurality of heat sources, wherein the working fluid flows through the first manifold (<NUM>), and
a plurality of first thermal conducting devices (<NUM>), wherein each of the first thermal conducting devices (<NUM>) is formed as a plate with a first end extending along the longitudinal axis, and wherein the first end is disposed within one of the slots (<NUM>) of the first elongated intermediate frame members (<NUM>) to position the first thermal conducting device (<NUM>) adjacent at least one of the plurality of heat sources (<NUM>), and wherein a second end of the first thermal conducting device (<NUM>) opposite the first end is disposed outside of the slot (<NUM>).