Abstract: Embodiments of the subject technology describe a modular thermal management system for battery packs with a bottom thermal component that seals the energy volume and provides structural support, and a top thermal component as a floating structure. A first support layer connects the bottom thermal component to the base plate, while a second support layer isolates the battery subassemblies from a top lid. The system offers flexibility with single or dual thermal component configurations, optimizing for performance or cost. The dual thermal component configuration improves charging times and thermal management for demanding applications, such as steep-gradient operations in high ambient temperatures, facilitating performance stability. The single thermal component option reduces cost for less demanding scenarios. Features like turbulent flow or dimples enhance cooling, while integration of a secondary cooling loop using different refrigerants increases capacity without significantly raising costs.

Abstract: Multiple thermal components for thermal regulation of batteries is provided. An electric vehicle can include a first thermal component configured to provide a thermal management function to a first side of a plurality of battery subassemblies. The electric vehicle also includes a plurality of second thermal components with each configured to provide the thermal management function to a second side of the plurality of battery subassemblies that opposes the first side. The first thermal component circulates a fluid through the first thermal component along a first axis and distributes the fluid along a second axis orthogonal to the first axis to each of the second thermal components through a cross member located between respective ones of the plurality of second thermal components. The first thermal component can form a lid for a battery pack and may function as a structural element to serve as a floor of the electric vehicle.