Abstract: A flexible sheet having enhanced thermal conductivity, electrical isolation and bonding strength includes a first layer of polyethylene terephthalate having opposed first and second sides and an electrical isolation of at least 500 ohms at 2.0 kV DC, and a second layer of heat-activated adhesive attached to and covering the first side. The heat-activated adhesive has a bonding strength of greater than 50 psi, and the first and second layers together have a thermal conductivity of at least 0.7 W/mK. A thermal cooling structure for use with high-voltage battery applications includes the first layer of polyethylene terephthalate, the second layer of heat-activated adhesive, a third layer of thermal interface material attached to and covering the second side of the first layer, and a metallic cooling plate attached to the second layer.

Abstract: A battery comprising a housing including a top plate and a bottom plate. The battery comprises a first battery cell stack comprising a first plurality of battery cells; a second battery cell stack comprising a second plurality of battery cells; a cold plate inserted between the first and second battery cell stacks, the cold plate in contact with the top plate and the bottom plate of the housing; and iv) a thermal adhesive injected into a first region between the cold plate and the first battery cell stack and substantially filling the first region.

Abstract: Provided herein are battery packs comprising a first polymeric endplate, a second polymeric endplate, and a plurality (n) of partitions extending between the first endplate and second endplate and defining (n?1) battery cavities. Each cavity is capable of receiving a battery cell stack comprising a plurality of battery cells and optionally cooling plates and foam pads. Partitions comprise a plurality of polymeric repeating spacers, and each spacer from each partition can correspond to a cooling plate common to a plurality of battery cell stacks. Each of the repeating spacers and cooling plates can include a plurality of aligned apertures, and corresponding bolts can occupy the aligned apertures and secure the same to the endplates. Each repeating spacer can correspond to a complete or partial battery unit, wherein a complete battery unit comprises a first battery cell, a cooling plate, a second battery cell, and a foam pad.

Abstract: Provided herein are battery packs comprising a first polymeric endplate, a second polymeric endplate, and a plurality (n) of partitions extending between the first endplate and second endplate and defining (n?1) battery cavities. Each cavity is capable of receiving a battery cell stack comprising a plurality of battery cells and optionally cooling plates and foam pads. Partitions comprise a plurality of polymeric repeating spacers, and each spacer from each partition can correspond to a cooling plate common to a plurality of battery cell stacks. Each of the repeating spacers and cooling plates can include a plurality of aligned apertures, and corresponding bolts can occupy the aligned apertures and secure the same to the endplates. Each repeating spacer can correspond to a complete or partial battery unit, wherein a complete battery unit comprises a first battery cell, a cooling plate, a second battery cell, and a foam pad.