Battery Array Cooling Side Capabilities
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Solution Overview
Problem
Conventional traction battery packs face challenges in achieving efficient cooling and assembly flexibility due to complex manufacturing processes and the need for specific mounting configurations that limit energy density and simplify assembly.
Innovation Solution
The battery array design incorporates thermal interface materials between the battery cells and top and bottom plates, along with mounting flanges on side plates, allowing for cooling from multiple sides and flexible assembly by centering the mounting flanges and using heat exchanger plates for enhanced thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mounting configurations are used, then assembly is simplified, but cooling capacity and energy density are limited
Solution Approach 1:
The side plates are designed with mounting flanges that serve dual purposes: providing structural support for assembly and enabling flexible mounting configurations. The flanges include multiple mounting holes arranged in different patterns, allowing the same component to accommodate various cooling plate arrangements and mounting locations, thereby achieving both assembly simplicity and enhanced cooling capacity.
Solution Approach 2:
The mounting flange design allows for dynamic configuration selection during assembly. By providing multiple hole patterns and flexible mounting options, the system can adapt to different cooling requirements and energy density targets without requiring completely different structural designs, thus resolving the contradiction between assembly simplicity and cooling performance.
2Temperature
If specific mounting configurations are required, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The side plates feature asymmetric mounting flange designs with non-uniform hole patterns positioned at specific locations. This asymmetry is deliberately designed to optimize thermal management by aligning mounting holes with optimal cooling plate positions, thereby achieving improved cooling efficiency without requiring complex custom configurations for each application.
Solution Approach 2:
The mounting flanges are pre-configured with multiple hole patterns during manufacturing, anticipating different cooling requirements before assembly. This preliminary preparation eliminates the need for complex field modifications or custom drilling operations, reducing device complexity while maintaining cooling efficiency.
3Quantity of substance
If energy density is increased, then vehicle range is improved, but thermal management challenges increase
Solution Approach 1:
The side plate mounting flanges extend the thermal management solution into the lateral dimension by providing multiple mounting holes that accommodate cooling plates positioned at different locations along the side of the battery array. This dimensional approach allows for enhanced heat dissipation from high-density battery configurations without compromising energy density.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances assembly flexibility, simplifies the mounting process, and increases cooling capacity, enabling higher energy density and efficient thermal management in traction battery packs.
Implementation Method 1
a first thermal interface material disposed between the top plate and the battery cell, and a second thermal interface material disposed between the bottom plate and the battery cell
Implementation Method 2
a heat exchanger plate is positioned atop the top plate
Data Source
AI summary
Battery array designs for electrified vehicle battery packs may include a thermal interface material disposed between battery cells of the array and both a top plate and a bottom plate of an array support structure. The battery array may therefore be configured to transfer heat through the top, bottom, or both. The battery array may further include a mounting flange located an equal distance from both the top plate and the bottom plate along a side plate of the array support structure. The battery array therefore provides a symmetrical design that simplifies assembly.