Abstract: A method of making a cold plate includes stacking three aluminum sheets on top of each other while each of the three aluminum sheets is generally flat. An edge of the three aluminum sheets are secured together. A top one of the aluminum sheets is welded to a middle one of the aluminum sheets at a plurality of first locations and a bottom one of the aluminum sheets is welded to the middle one of the aluminum sheets at a plurality of second locations different than the plurality of first locations. A pressurized medium is supplied between the top one of the aluminum sheets and the bottom one of the aluminum sheets to separate the top one of the aluminum sheets from the bottom one of the aluminum sheets and deform the middle one of the aluminum sheets.

Abstract: A system, in accordance with a non-limiting example, includes a first member including a first electrical connector and a second member including a second electrical connector. The first member includes a rigid base and a resilient connector support coupled to the rigid base. The first electrical connector is being mounted to the resilient connector support.

Abstract: A coolant containment system for a battery pack includes a coolant retention container defining a containment space, an inlet connected to the coolant retention container, the inlet connected to an inlet line configured to receive a coolant, an outlet connected to the coolant retention container, the outlet connected to an outlet line, the outlet line configured return a coolant, a drain plug connected to the coolant retention container and in communication with the containment space. The inlet line and the outlet line are disposed entirely within the containment space and any coolant from a leak is retained within the containment space and exits the containment space to an environment outside the battery tray via the drain plug.

Abstract: An immersion cooling system for a battery system includes a battery enclosure and G battery cell groups arranged in the battery enclosure. Each of the G battery cell groups include C battery cells, where G and C are integers greater than one. A plurality of dividers are arranged between each of the G battery cell groups. A gas manifold removes vent gases from each of the G battery cell groups.

Abstract: Presented are thermal management systems using coolant flow distribution plates for immersion cooling of battery cells, methods for making/using such systems, and vehicles equipped with such systems for cooling the vehicles' battery packs. A battery assembly includes multiple battery cells arranged in adjacent, mutually parallel cell rows. The battery cells are stored inside a protective battery housing that includes inlet and outlet fluid ports for receiving and evacuating therethrough dielectric coolant fluid. A pair of (first and second) separator plates is located between each neighboring pair of cell rows. Each plate includes coolant channels that are arranged in mutually parallel channel bands. The separator plates are in face-to-face contact with each other such that each channel band of the first separator plate is aligned with a respective channel band of the second plate so the coolant channels cooperatively distribute coolant fluid onto and vertically upward between the battery cells.

Abstract: An immersion cooling system for a battery system includes a battery enclosure and G battery cell groups arranged in the battery enclosure. Each of the G battery cell groups include C battery cells, where G and C are integers greater than one. A plurality of dividers are arranged between each of the G battery cell groups. A gas manifold removes vent gases from each of the G battery cell groups.

Abstract: An immersion cooling system for a battery system includes a battery enclosure and C metal-encased, pouch-type battery cells including C metal cases, C pouch-type battery cells arranged in the C metal cases, respectively, where C is an integer greater than one, and C vents on the C metal cases, respectively. A vent gas manifold is in fluid communication with the C vents of the C metal cases and is configured to remove vent gas passing through the C vents of the C metal cases from the battery enclosure.