Integrated cooling fin and frame

1. An integrated cooling fin and frame comprising:

a generally planar cooling fin having at least one cooling channel formed adjacent to a surface and at least one edge thereof, the cooling channel having an inlet and an outlet; and

a frame configured to be placed around the cooling fin and the cooling channel to cover the edges of the cooling fin and a substantial entirety of the cooling channel, the frame having a first opening formed therein for the inlet and a second opening formed therein for the outlet of the cooling channel.

2. The integrated cooling fin and frame of claim 1 wherein the cooling fin is made of a thermally conductive material.

3. The integrated cooling fin and frame of claim 2 wherein the thermally conductive material is aluminum, alumina, copper, aluminum silicon carbide, beryllium oxide, or combinations thereof.

4. The integrated cooling fin and frame of claim 1 wherein the frame has at least one hole for a mechanical connector.

5. The integrated cooling fin and frame of claim 1 wherein the frame has a tab with a hole for a mechanical connector.

6. The integrated cooling fin and frame of claim 1 wherein the cooling channel extends around three edges.

7. The integrated cooling fin and frame of claim 1 wherein the cooling channel extends around four edges.

8. The integrated cooling fin and frame of claim 1 wherein the cooling fin comprises a pair of thermally conductive plates separated by a layer of an expansion compensator.

9. The integrated cooling fin and frame of claim 8

wherein the expansion compensator is a compressible foam.

10. A battery pack comprising;

a pair of end frames, one end frame having a positive terminal and the other end frame having a negative terminal;

at least one integrated cooling fin and frame comprising:

a generally planar cooling fin having a cooling channel formed adjacent to a surface and at least one edge thereof, the cooling channel having an inlet and an outlet; and

a frame configured to be placed around the cooling fin and the cooling channel to cover the edges of the cooling fin and a substantial entirety of the cooling channel, the frame having a first opening formed therein for the inlet and a second opening formed therein for the outlet of the cooling channel;

a plurality of battery cells placed within the integrated cooling fin and frame, each of the plurality of battery cells having a positive tab and a negative tab, the positive tab of one of the plurality of battery cells electrically connected to the positive terminal, and the negative tab of another one of the plurality of battery cells electrically connected to the negative terminal, the integrated cooling fin and frame cooperative to electrically isolate edges of each of the plurality of battery cells from the cooling fin by the covering of the edge of the cooling fin with the frame;

at least one power connector electrically connecting the negative tab of one of the battery cells with the positive tab of an adjacent one of the plurality of battery cells; and

a fluid manifold connected to the cooling channel inlet and outlet for circulating fluid to the cooling channel.

11. The battery pack of claim 10 wherein the cooling fin is made of a thermally conductive material.

12. The battery pack of claim 11 wherein the thermally conductive material is aluminum, alumina, copper, aluminum silicon carbide, beryllium oxide, or combinations thereof.

13. The battery pack of claim 10 wherein the frame has at least one hole for a mechanical connector.

14. The battery pack of claim 10 wherein the frame has a tab with a hole for a mechanical connector.

15. The battery pack of claim 10 wherein the cooling channel extends around three edges.

16. The battery pack of claim 10

wherein the integrated cooling fin and frame electrically isolate the cell tabs from the cooling fin.

17. The battery pack of claim 10 wherein the cooling fin comprises a pair of thermally conductive plates separated by a layer of an expansion compensator.

18. A method of making an integrated cooling fin and frame comprising:

providing a generally planar cooling fin having a cooling channel formed adjacent to a surface and on at least one edge thereof, the cooling channel having an inlet and an outlet; and

molding a frame around the cooling fin so that the frame:

covers a substantial entirety of the cooling channel and the edges of the cooling fin;

seals the cooling fin to the frame, and

has an opening for the inlet and an opening for the outlet of the cooling channel.

19. The method of claim 18 wherein the frame is molded using injection molding.