Patent ID: 8263250

Claim:
A thermal management system for use with a battery pack, the battery pack comprised of a plurality of substantially cylindrical cells arranged into at least a first row of cells and a second row of cells, wherein said first row of cells is adjacent to said second row of cells, and wherein said first row of cells is offset from said second row of cells, said system comprising: a liquid cooling manifold assembly interposed between said first and second rows of cells, said liquid cooling manifold comprising: a coolant channel portion, said coolant channel portion including at least one coolant channel, wherein said coolant channel portion is comprised of a first surface adjacent to said first row of cells and a second surface adjacent to said second row of cells, and wherein said coolant channel portion is comprised of a first plurality of contours coinciding with said cells of said first row of cells and a second plurality of contours coinciding with said cells of said second row of cells, and wherein said first and second pluralities of contours alternate; a first dual layer thermal interface interposed between said first surface and said first row of cells, wherein said first dual layer thermal interface is comprised of an inner material layer adjacent to said first surface and an outer material layer adjacent to said first row of cells; a second dual layer thermal interface interposed between said second surface and said second row of cells, wherein said second dual layer thermal interface is comprised of said inner material layer adjacent to said second surface and said outer material layer adjacent to said second row of cells; and wherein said inner material layer is fabricated from a compressible material with a modulus of compressibility of less than 3 MPa and said outer material layer is fabricated from a dielectric material with a breakdown voltage of greater than 500 VDC, and wherein said inner and outer material layers are comprised of different materials.