Abstract: A forming device is configured to form metal laminated sheet material into a tray-shaped case half while allowing the material to form pleats in the corners of the recess during the forming process while preventing formation of pleats along the flange. The device forms the flange so that excess material in the corners of the case halves is arranged in an undulating shape. As a result, the flange has a waved or ruffled configuration at each corner. Two such case halves are sealed together along the flange to form a reliably sealed package. A method of forming pouch cell is also described.

Abstract: A battery pack including a battery pack housing, and a battery module disposed in the battery pack housing, Tire pack housing is sealed and flooded with a dielectric fluid. The battery module includes a module housing that is fluid permeable and includes a fluid passageway, and electrochemical cells disposed in the module housing in such a way that terminals of the cells are exposed to fluid disposed in the fluid passageway. The battery pack includes a thermal management system having an inlet plenum assembly disposed at a first end of the battery module, an outlet plenum assembly disposed at a second end of the battery module, and a fluid pump that directs fluid to the inlet plenum assembly via a fluid delivery line and receives fluid from the outlet plenum assembly via a fluid return line.

Abstract: A forming device is configured to form metal laminated sheet material into a tray-shaped case half while allowing the material to form pleats in the corners of the recess during the forming process while preventing formation of pleats along the flange. The device forms the flange so that excess material in the corners of the case halves is arranged in an undulating shape. As a result, the flange has a waved or ruffled configuration at each corner. Two such case halves are sealed together along the flange to form a reliably sealed package. A method of forming pouch cell is also described.