METHOD OF STRUCTURAL BATTERY COOLING PLATE DESIGN FOR ELECTRIC OR HYBRID VEHICLE OR ELECTRICAL ENERGY STORAGE SYSTEM APPLICATION

Manufacture and quality control of a cooling plate is simplified by providing peripheral walls on each side of a fluid cavity within a metallic base. The peripheral walls protrude over external surfaces of a fluid cavity and encircle open recesses. The external surface of the fluid cavity on one side of the base may be a metallic lid surrounded by a ledge inside the peripheral walls on the respective side and over the fluid cavity, joined to the base by friction stir welding. Plastic honeycomb cell receptacle structures within the open recesses on each side of the base may be snap fit to counterpart features on the peripheral walls. Defects arising from machining, e-coating, or powder coating metallic cell pockets on the cooling plate are avoided, as are defects related to gravity casting of the base for some embodiments.