Multi-Function Barrier Tray for Battery Pack Electrical Isolation
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Solution Overview
Problem
Existing traction battery packs face challenges in maintaining electrical isolation between battery cells and heat exchanger plates, while also providing suitable interfaces for thermal management and structural integrity.
Innovation Solution
The implementation of a multi-function barrier tray positioned between the battery cell stack and the heat exchanger plate, featuring a ladder frame-like configuration with an outer frame and legs, pockets for battery cell fins, and flat surfaces for interfacing with thermal barrier assemblies and end plates, ensures electrical isolation and effective thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier tray is positioned between the battery cell stack and the heat exchanger plate to maintain electrical isolation, then electrical isolation is improved, but device complexity increases
Solution Approach 1:
The barrier tray is designed to perform multiple functions simultaneously: it provides electrical isolation between the battery cell stack and heat exchanger plate, supports the battery cell stack, provides thermal management interfaces through pockets for battery cell fins, and offers structural reinforcement. This multi-functionality reduces the need for separate components, thereby improving electrical isolation without proportionally increasing device complexity.
2Temperature
If the barrier tray includes pockets for receiving battery cell fins to provide thermal management interfaces, then thermal management effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The barrier tray is segmented into multiple functional zones including pockets for receiving battery cell fins, flat surfaces for thermal barrier assembly interfaces, and structural support sections. This segmentation allows each zone to be optimized for its specific function while maintaining a unified component structure, improving thermal management effectiveness without excessive manufacturing complexity.
3Strength
If the barrier tray provides flat surfaces for interfacing with thermal barrier assemblies and end plates, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The barrier tray merges structural support functions with thermal management and electrical isolation functions into a single integrated component. The flat surfaces for interfacing with thermal barrier assemblies and end plates are incorporated directly into the barrier tray structure, providing structural integrity while avoiding the need for separate support components that would increase device complexity.
Data Source
AI summary
Multi-functional barrier trays are provided for use within traction battery packs. An exemplary barrier tray may be arranged between a heat exchanger plate and a cell stack of the traction battery pack for maintaining electrical isolation between battery cells of the cell stack and the heat exchanger plate, providing flat surfaces for cell stack thermal barrier and end plate components to interface relative to, and sealing interfaces between the cell stack and the heat exchanger plate.