DESC:A COOLING PLATE AND METHOD OF MANUFACTURE THEREOF
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202421049562 filed on 28/06/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to a battery pack. Particularly, the present disclosure relates to a cooling plate for a battery pack of an electric vehicle. Furthermore, the present disclosure relates to a method of manufacturing a cooling plate for a battery pack of an electric vehicle.
BACKGROUND
Recently, there has been a rapid development in battery packs because of their use as clean energy storage solution for various uses ranging from domestic use to transportation use. The battery pack comprises a set of any number of identical batteries or individual battery cells. The battery cells are assembled as cell arrays and multiple cell arrays are combined to form the battery packs.
Each battery pack comprises a plurality of cells and cell holders for securing the plurality of cells. These battery cells are electrically connected to form cell arrays and multiple cell arrays can be stacked together to form the battery pack, being used as a single unit for meeting high voltage and current requirements. However, the battery pack generates a large amount of heat during the charging and discharging process. If heat generated during the charging and discharging process is not effectively eliminated, heat accumulation may occur inside the battery, which results in accelerated deterioration of the battery cells. Moreover, in some conditions such heat accumulation may even lead to hotspots causing thermal runaway which would permanently damage the battery pack. Furthermore, the thermal runaway may lead to fire and/or explosion causing safety risks.
Generally, to eliminate the heat and prevent resultant damages, a cooling jacket is placed on the outer surfaces such as the casing of the battery pack. However, such a cooling structure can only extract heat from the outer portions of the battery pack, leaving the inner portions of the battery pack at a higher temperature. Thus, a temperature gradient is formed between the inner and outer portion of the battery pack which leads to poor cell performance and higher degradation rate. To reduce the temperature gradient and extract heat from the inner portions of the battery pack, a submerged cooling technique is used wherein all the battery cells of the battery pack are submerged in a coolant. The battery pack with coolant-submerged battery cells have a lower temperature gradient between the outer and inner portions of the battery pack. However, the use of such a cooling technique leads to an increase in the weight of the battery pack. Furthermore, the size and cost of the battery pack is also increased significantly. Moreover, such cooling techniques add unnecessary bulk to the already bulky battery pack. Furthermore, the added weight and size affects the performance of the battery pack in mobile application such as electric vehicles.
Therefore, there exists a need of an improved solution for a cooling plate of a battery pack that overcomes one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a cooling plate for a battery pack of an electric vehicle.
Another object of the present disclosure is to provide a method of manufacturing a cooling plate for a battery pack of an electric vehicle.
In accordance with first aspect of the present disclosure, there is provided a cooling plate for a battery pack of an electric vehicle. The cooling plate is made of a composite material. The composite material comprises a thermoplastic-matrix and a thermally conductive filler material dispersed within the thermoplastic-matrix. The cooling plate is formed by additive manufacturing.
The present disclosure provides the cooling plate for the battery pack of the electric vehicle. The cooling plate as disclosed by present disclosure is advantageous for enhancing the thermal management of electric vehicle (EV) battery packs. Beneficially, the cooling plate ensures the effective heat dissipation from battery cells, which is critical for maintaining battery performance, safety, and longevity. Furthermore, the cooling plate provides lightweight, corrosion-resistant, and structurally stable properties which makes the cooling plate suitable for automotive environments. Additionally, the cooling plate enhances the overall thermal performance of the plate. Moreover, the cooling plate optimizes the surface area for heat dissipation. Beneficially, the cooling plate supports to the design customization and weight reduction. Moreover, the cooling plate contributes to the improved system efficiency and battery reliability in the electric vehicles.
In accordance with second aspect of the present disclosure, there is provided a method of manufacturing a cooling plate for a battery pack of an electric vehicle. The method comprising preparing a composite material by mixing a thermoplastic-matrix with a thermally conductive filler material and additively manufacturing the composite material to form the cooling plate.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1a illustrates a perspective view of a cooling plate for a battery pack of an electric vehicle, in accordance with an aspect of the present disclosure.
FIG. 1b illustrates a zoomed view of a composite material, in accordance with an embodiment of the present disclosure.
FIG. 2 illustrates a flow chart of a method of manufacturing a cooling plate for a battery pack of an electric vehicle, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a cooling plate for a battery pack of an electric vehicle and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheeler, electric three-wheeler, electric four-wheeler, electric pickup trucks, electric trucks and so forth.
As used herein, the term “cooling plate” refers to a thermally functional structural component configured to be positioned in thermal communication with one or more battery cells of a battery pack, and adapted to facilitate the dissipation or redistribution of heat generated during battery operation. The cooling plate may be formed from thermally conductive materials and may include integrated or surface features such as channels, fins, or lattice structures to enhance heat transfer.
As used herein, the terms “battery pack” refers to an assembly of one or more rechargeable electrochemical cells (such as lithium-ion, lithium iron phosphate, or similar types) that are electrically connected to provide a specified voltage and capacity. The battery pack includes the cells, electrical interconnections, a housing or casing for structural support and protection, and may further comprise additional components such as a battery management system (BMS), thermal management systems, insulation layers, sensors, and electrical connectors. The battery pack is configured to store and deliver electrical energy to power a load, such as an electric motor in an electric vehicle.
As used herein, the term “composite material” refers to a material system composed of two or more distinct constituent materials that remain chemically separate within the final structure, wherein the constituents are combined to achieve properties that are superior or significantly different from those of the individual components. Typically, a composite material comprises a matrix material, which forms the continuous phase, and a reinforcement or filler material, which is embedded within the matrix to enhance specific mechanical, thermal, or electrical properties. The composite material comprises a thermoplastic matrix and a thermally conductive filler material dispersed within the matrix to improve thermal conductivity while maintaining structural integrity and processability.
As used herein, the term “thermoplastic matrix” refers to the continuous phase of a composite material composed of a thermoplastic polymer, which serves as the primary binding and structural medium in which filler materials are uniformly dispersed. The thermoplastic matrix provides mechanical integrity, shape retention, and processability to the composite. The suitable thermoplastic matrices include, but are not limited to, epoxy, polycarbonate, polycarbonate blends, polyphenylene ether, polypropylene, and polyethylene terephthalate. The selection of the thermoplastic matrix may be based on desired mechanical strength, thermal stability, chemical resistance, and compatibility with thermally conductive filler materials.
As used herein, the term “thermally conductive filler” refers to a material or a combination of materials that are dispersed within a base matrix (such as a polymer or thermoplastic) to enhance the ability to conduct heat. The thermally conductive fillers are characterized by having a higher thermal conductivity than the surrounding matrix material and are incorporated to form a thermally conductive path, thereby improving the overall thermal performance of the composite. The thermally conductive filler may include, but is not limited to, one or more of: carbon-based materials (such as graphite, graphene, single-walled carbon nanotubes, or multi-walled carbon nanotubes), ceramic materials (such as boron nitride or aluminium nitride), or metallic particles (such as copper or aluminium), which may be in the form of particles, flakes, fibres, or nanostructures.
As used herein, the term “additive manufacturing” refers to a process of fabricating a three-dimensional object by successively depositing material layer by layer based on a digital model, wherein the object is formed by the addition of material rather than by subtractive methods such as cutting or machining. The additive manufacturing process may include, but is not limited to, techniques such as fused deposition modelling (FDM), selective laser sintering (SLS), stereolithography (SLA), direct energy deposition (DED), or binder jetting, depending on the type of material and desired structural configuration.
As used herein, the term “plurality of single-walled nanotubes” and “single-walled nanotubes” are used interchangeably and refer to a composition including multiple individual carbon nanotubes, each comprising a single cylindrical layer of carbon atoms arranged in a hexagonal lattice structure. The single-walled nanotubes are typically formed as seamless tubes of graphene and exhibit high thermal conductivity, mechanical strength, and electrical conductivity.
As used herein, the term “plurality of multi-walled nanotubes” and “multi-walled nanotubes” are used interchangeably and refer to a collection of multiple carbon nanotube structures, each comprising multiple concentric cylindrical graphene layers (walls) arranged in a coaxial manner around a common central axis. The multi-walled carbon nanotubes exhibit high thermal conductivity, mechanical strength, and chemical stability.
As used herein, the term “continuous network” refers to an interconnected structure formed by the thermally conductive filler material within the thermoplastic matrix, wherein the filler material establishes a substantially uninterrupted thermal conduction pathway across the matrix. The network enables efficient transfer and distribution of heat throughout the composite material by creating multiple points of contact between adjacent filler particles, such that thermal energy can traverse through the filler network without substantial reliance on the surrounding thermoplastic matrix.
As used herein, the term “thermal conductivity” refers to the intrinsic property of a material that quantifies its ability to conduct heat. The thermal conductivity defined as the rate at which heat passes through a unit area of the material, having a unit thickness, when subjected to a unit temperature gradient under steady-state conditions. The thermal conductivity is typically expressed in units of watts per meter-kelvin (W/m·K), and higher thermal conductivity values indicate greater efficiency in transferring heat through the material.
As used herein, the term “liquid cooling system” refers to a thermal management system configured to regulate the temperature of a component such as a battery pack by circulating a liquid coolant through one or more fluidic channels, conduits, or chambers in thermal communication with the component. The liquid coolant absorbs heat from the component and transfers the coolant to a remote heat exchanger or radiator, where the heat is dissipated to the ambient environment. The system may include elements such as a coolant reservoir, pump, valves, sensors, and control electronics to ensure stable and efficient operation under varying thermal loads. The liquid coolant may comprise water, glycol-based mixtures, dielectric fluids, or any suitable fluid with desired thermal and chemical properties.
As used herein, the term “phase change material cooling system” and “PCM” are used interchangeably and refer to a thermal management system that utilizes a material capable of absorbing and releasing a significant amount of latent heat during its phase transition, typically from solid to liquid or vice versa, at a specific temperature range. The phase change material is positioned in thermal contact with the battery cells or integrated within the cooling plate. During battery operation, when the temperature increases beyond a threshold, the PCM absorbs heat and undergoes a phase change, thereby regulating the temperature by delaying further rise. Upon cooling, the PCM re-solidifies, releasing the stored thermal energy. This passive cooling approach helps maintain battery temperature within optimal operating limits, enhancing battery performance, safety, and cycle life without requiring continuous energy input.
Figure 1a & 1b, in accordance with an embodiment describes a cooling plate 100 for a battery pack of an electric vehicle. The cooling plate 100 is made of a composite material. The composite material comprises a thermoplastic-matrix 102 and a thermally conductive filler material 104 dispersed within the thermoplastic-matrix 102. The cooling plate 100 is formed by additive manufacturing.
In an embodiment, the thermoplastic-matrix 102 is selected from at least one of epoxy, polycarbonate, polycarbonate blends, polyphenylene ether, polypropylene, or polyethylene terephthalate. The selection of the thermoplastic materials allows the cooling plate 100 to exhibit desirable characteristics such as high thermal stability, good mechanical strength, chemical resistance, and processability suitable for additive manufacturing. For instance, polycarbonate and the polycarbonate blends offer impact resistance and high heat deflection temperature, while polypropylene and polyethylene terephthalate provide lightweight properties and good dimensional stability. The epoxy and polyphenylene ether enhance thermal and electrical insulation characteristics. The thermoplastic- matrix 102 act as the primary structural framework in which thermally conductive filler materials 104 are uniformly dispersed, thereby enables the cooling plate 100 to serve as an efficient thermal interface in the battery pack of the electric vehicle.
In an embodiment, the thermally conductive filler material 104 is selected from at least one of a plurality of single-walled carbon nanotubes, a plurality of multi-walled carbon nanotubes, boron nitride, or a plurality of nanoparticles. The thermally conductive filler materials 104 may be uniformly dispersed within the thermoplastic matrix 102 to form the composite structure that enhances the overall thermal conductivity of the cooling plate 100. The selected filler materials possess the high intrinsic thermal conductivity and are effective in forming the conductive pathways for efficient heat dissipation from the battery cells during vehicle operation. The use of carbon nanotubes, in both single-walled and multi-walled forms, provides the exceptional thermal transfer due to the high aspect ratio and conductive nature. Alternatively, the boron nitride offers high thermal conductivity with electrical insulation, which is advantageous for avoiding short circuits in electrically sensitive battery environments. Subsequently, the use of nanoparticles, depending on the composition and dispersion, contributes to improving the thermal performance by reducing thermal resistance across the composite structure. Beneficially, the conductive filler material 104 ensures that the cooling plate 100 maintains the uniform thermal gradients and supports efficient heat removal, thereby protecting the battery pack from thermal stress and enhancing operational reliability.
In an embodiment, the thermally conductive filler material 104 forms a continuous network within the thermoplastic-matrix 102 to enhance thermal conductivity. The continuous network of the thermally filler material 104 may be structured such that the filler material 114 creates an uninterrupted thermal pathway across the body of the cooling plate 100, thereby significantly enhances the effective thermal conductivity of the composite. The network structure enables rapid and uniform heat transfer away from localized high-temperature regions, such as those occurring near the battery cell interfaces. The formation of the continuous network may be achieved through controlled dispersion techniques during the composite formulation and through directional deposition methods facilitated by additive manufacturing processes. As a result, the thermal management efficiency of the cooling plate 100 is improved, supporting stable battery operation, preventing overheating and contributing to the prolonged life and performance of the battery pack.
In an embodiment, the cooling plate 100 comprises at least one of fins, channels, or lattice structures to increase heat dissipation efficiency. The structural features may be configured to increase the effective surface area of the cooling plate 100, thereby improving the thermal exchange with the surrounding environment or with a secondary cooling medium such as air or liquid. The fins may be oriented vertically or horizontally depending on the installation geometry, while the channels may be designed to allow the flow of coolant fluid through or along the cooling plate 100. Alternatively, or in addition, the lattice structures may be formed within or on the surface of the plate to promote multi-directional heat conduction and dissipation. Beneficially, the structural features are enabled using additive manufacturing techniques, which allow the precise fabrication of complex geometries directly into the cooling plate 100 without the need for secondary assembly operations. Moreover, the integration of such geometrical enhancements contributes to improved thermal management of the battery pack, enables more uniform temperature distribution and reduces the risk of thermal runaway.
In an embodiment, the cooling plate 100 is configured to be integrated with a liquid cooling system or a phase change material cooling system. The integration with the liquid cooling system enhances the thermal regulation of the battery pack. Moreover, the liquid cooling system may involve embedding one or more fluid channels within or adjacent to the cooling plate 100, allows a coolant to flow through and actively extract heat from the battery cells. The thermally conductive filler material 104 of the cooling plate 100 facilitates the efficient heat transfer from the battery cells to the circulating coolant, thereby maintaining optimal battery operating temperatures. Alternatively, the cooling plate 100 may be designed to interface with or encapsulate the phase change material, which passively absorbs the heat by undergoing a solid-to-liquid phase transition. In the PCM based configuration, the PCM is positioned in thermal communication with the surface of the cooling plate 100 or embedded within the structure, such that as the battery generates heat during operation, the PCM absorbs the heat and transitions phases, thereby preventing the rapid temperature rise. The dual compatibility with both active and passive cooling mechanisms provides the cooling plate 100 with enhanced versatility and adaptability for use in various electric vehicle battery architectures.
The present disclosure provides the cooling plate 100 for the battery pack of the electric vehicle. The coolant plate as disclosed by present disclosure is advantageous in terms of the efficient and reliable thermal management of electric vehicle battery packs. Beneficially, by utilizing the composite material comprising the thermoplastic matrix 102 and the thermally conductive filler material 104, the cooling plate 100 ensures an optimized balance between mechanical integrity, weight reduction, and thermal performance. Beneficially, the thermoplastic matrix 102 offers the lightweight and corrosion-resistant properties while maintaining the structural flexibility, making the cooling plate 100 suitable for integration into compact EV battery modules. The inclusion of the high-performance conductive filler materials 104 such as the carbon nanotubes, boron nitride, or nanoparticles allows the formation of the thermally conductive network, significantly improves the heat transfer across the cooling plate 100 and mitigating local hotspots that may degrade battery performance. Moreover, the use of additive manufacturing enables complex geometric features such as integrated fins, channels, or lattice structures, which further enhance the convective and conductive heat dissipation efficiency without requiring post-processing. The additive manufacturing approach also allows for design optimization, weight savings, and scalable production. Additionally, the cooling plate 100 may be seamlessly configured for integration with both liquid cooling and phase change material (PCM) cooling systems, thereby increasing the applicability across different EV architectures and thermal control strategies. The integration with PCM systems provides the passive thermal buffer by utilizing latent heat, while liquid systems offer active cooling potential, together offering flexible and modular cooling solutions.
In an embodiment, the cooling plate 100 for the battery pack of the electric vehicle is disclosed. The cooling plate 100 is made of the composite material. The composite material comprises the thermoplastic-matrix 102 and the thermally conductive filler material 104 dispersed within the thermoplastic-matrix 102. The cooling plate 100 is formed by additive manufacturing. Furthermore, the thermoplastic-matrix 102 is selected from the at least one of epoxy, polycarbonate, polycarbonate blends, polyphenylene ether, polypropylene, or polyethylene terephthalate. Furthermore, the thermally conductive filler material 104 is selected from the at least one of the plurality of single-walled carbon nanotubes, the plurality of multi-walled carbon nanotubes, boron nitride, or the plurality of nanoparticles. Furthermore, the thermally conductive filler material 104 forms the continuous network within the thermoplastic-matrix 102 to enhance thermal conductivity. Furthermore, the cooling plate 100 comprises the at least one of fins, channels, or lattice structures to increase heat dissipation efficiency. Furthermore, the cooling plate 100 is configured to be integrated with the liquid cooling system or the phase change material cooling system.
Figure 2, describes a method 200 of manufacturing a cooling plate 100 for a battery pack of an electric vehicle. The method 200 starts at step 202 and completes at step 204. At step 202, the method 200 comprises preparing a composite material by mixing a thermoplastic-matrix 102 with a thermally conductive filler material 104. At step 204, the method 200 comprises additively manufacturing the composite material to form the cooling plate 100.
In an embodiment, the additive manufacturing includes layer-by-layer deposition of the composite material.
In an embodiment, the method 200 comprising post-processing the additively manufactured cooling plate 100 by curing or thermal treatment.
It would be appreciated that all the explanations and embodiments of the portable device 100 also applies mutatis-mutandis to the method 200.
In an embodiment, there is disclosed a cooling system for a battery pack of an electric vehicle comprising the cooling plate 100 and at least one additional cooling component selected from the group consisting of a liquid coolant and a phase change material. The cooling plate 100, which is formed by additive manufacturing using a composite material consisting of a thermoplastic matrix 102 and thermally conductive filler material 104, functions as a thermally conductive interface directly contacting the battery cells or positioned adjacent to the battery cells. The additional cooling component may be a liquid coolant circulated through integrated channels or external manifolds to actively remove heat from the cooling plate 100. Alternatively, or in combination, a phase change material may be integrated within or adjacent to the cooling plate 100 to passively absorb excess heat during phase transition, thereby buffering thermal spikes and maintaining the battery pack within an optimal temperature range. The hybrid cooling system enhances thermal performance through both active and passive means, offering improved thermal stability, design flexibility, and safety for electric vehicle battery packs under various operating conditions.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A cooling plate (100) for a battery pack of an electric vehicle, wherein the cooling plate (100) is made of a composite material, wherein the composite material comprises:
- a thermoplastic-matrix (102); and
- a thermally conductive filler material (104) dispersed within the thermoplastic-matrix (102),
wherein the cooling plate (100) is formed by additive manufacturing.
2. The cooling plate (100) as claimed in claim 1, wherein the thermoplastic-matrix (102) is selected from at least one of: epoxy, polycarbonate, polycarbonate blends, polyphenylene ether, polypropylene, or polyethylene terephthalate.
3. The cooling plate (100) as claimed in claim 1, wherein the thermally conductive filler material (104) is selected from at least one of: a plurality of single-walled carbon nanotubes, a plurality of multi-walled carbon nanotubes, boron nitride, or a plurality of nanoparticles.
4. The cooling plate (100) as claimed in claim 1, wherein the thermally conductive filler material (104) forms a continuous network within the thermoplastic-matrix (102) to enhance thermal conductivity.
5. The cooling plate (100) as claimed in claim 1, wherein the cooling plate (100) comprises at least one of: fins, channels, or lattice structures to increase heat dissipation efficiency.
6. The cooling plate (100) as claimed in claim 1, wherein the cooling plate (100) is configured to be integrated with a liquid cooling system or a phase change material cooling system.
7. A method (200) of manufacturing a cooling plate (100) for a battery pack of an electric vehicle, the method (200) comprising:
- preparing a composite material by mixing a thermoplastic-matrix (102) with a thermally conductive filler material (104); and
- additively manufacturing the composite material to form the cooling plate (100).
8. The method (200) as claimed in claim 7, wherein the additive manufacturing includes layer-by-layer deposition of the composite material.
9. The method (200) as claimed in claim 7, comprising post-processing the additively manufactured cooling plate (100) by curing or thermal treatment.
10. A cooling system for a battery pack of an electric vehicle, comprising:
- the cooling plate (100) as claimed in claim 1; and
- at least one additional cooling component selected from the group consisting of a liquid coolant and a phase change material.