Propulsion battery with pre-manufactured structural heat exchanger

A battery package, comprising:

• a first battery cell and a second battery cell;
• an expansion unit disposed between the first battery cell and the second battery cell;
• and a frame assembly including a frame body and a pair of frame covers, the frame body having a first recess, a second recess, and a central aperture disposed between the first recess and the second recess, the first recess receiving the first battery cell, the second recess receiving the second battery cell, and the central aperture receiving the expansion unit, each of the frame covers disposed adjacent one of the first recess and the second recess to hold the first battery cell, the second battery cell, and the expansion unit within the frame body.

A battery pack assembly, comprising;

• a plurality of battery packages, each of the battery packages including a first battery cell and a second battery cell, an expansion unit disposed between the first battery cell and the second battery cell, and a frame assembly including a frame body and a pair of frame covers, the frame body having a first recess, a second recess, and a central aperture disposed between the first recess and the second recess, the first recess receiving the first battery cell, the second recess receiving the second battery cell, and the central aperture receiving the expansion unit, each of the frame covers disposed adjacent one of the first recess and the second recess to hold the first battery cell, the second battery cell, and the expansion unit within the frame body;
• and
• a heat exchanger having a plurality of cooling fins, at least one of the cooling fins disposed between a pair of the plurality of battery packages.

A method for manufacturing a battery pack assembly, the method comprising the steps of:

• stacking a plurality of battery packages, each of the battery packages including a first battery cell and a second battery cell, an expansion unit disposed between the first battery cell and the second battery cell, and a frame assembly including a frame body and a pair of frame covers, the frame body having a first recess, a second recess, and a central aperture disposed between the first recess and the second recess, the first recess receiving the first battery cell, the second recess receiving the second battery cell, and the central aperture receiving the expansion unit, each of the frame covers disposed adjacent one of the first recess and the second recess to hold the first battery cell, the second battery cell, and the expansion unit within the frame body;
• and
• inserting the plurality of battery packages into a heat exchanger having a plurality of cooling fins, wherein at least one of the cooling fins is disposed between a pair of the plurality of battery packages.