Battery Pack Array Frame Design Without Thermal Fins
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Solution Overview
Problem
Conventional battery packs for electrified vehicles face challenges in efficiently managing heat generated by battery cells during charging and discharging operations, often relying on thermal fins that increase weight, cost, and packaging size.
Innovation Solution
The battery pack design incorporates a heat dissipating structure, such as a heat exchanger plate or thermal interface material, with an array frame that exposes at least one surface of the battery cell for direct contact, eliminating the need for thermal fins and leveraging internal thermally conductive paths within the battery cells for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal fins are used for heat management, then heat dissipation efficiency is improved, but weight increases
Solution Approach 1:
The patent removes thermal fins from the battery pack design entirely. Instead, it uses the battery cell casings themselves as heat dissipation surfaces, which are placed in direct contact with heat exchanger plates. This extraction of the thermal fin component eliminates the additional weight while maintaining heat management functionality through the cell casing-heat exchanger interface.
Solution Approach 2:
The battery cell casing serves dual functions: structural containment and thermal management. By designing the casing to act as both the structural envelope and the heat dissipation surface, the patent eliminates the need for separate thermal fins. The casing's external surface becomes the thermal interface with the heat exchanger plates, combining structural and thermal management roles in one component.
2Temperature
If thermal fins are used for heat management, then heat dissipation efficiency is improved, but cost increases
Solution Approach 1:
The patent eliminates thermal fins from the design, removing the associated manufacturing costs for these components. The heat dissipation function is transferred to the battery cell casings, which are already being manufactured as structural components, thereby avoiding additional material and assembly costs.
Solution Approach 2:
The battery cell casing is designed to perform both structural and thermal management functions. By making the casing the heat dissipation surface, the patent eliminates the need for separate thermal management components, reducing part count, material costs, and assembly complexity while maintaining effective heat transfer.
3Temperature
If thermal fins are used for heat management, then heat dissipation efficiency is improved, but packaging size increases
Solution Approach 1:
The patent removes thermal fins from the battery pack architecture. The heat dissipation function is achieved through the battery cell casings that are already present in the pack, eliminating the need for additional volumetric space dedicated to thermal fins and their mounting structures.
Solution Approach 2:
The battery cell casing serves as both the structural boundary and the thermal management surface. This multi-functionality eliminates the need for separate thermal fin structures that would occupy additional volume, allowing more compact battery pack packaging while maintaining effective heat dissipation through direct contact between cell casings and heat exchanger plates.
4Weight of moving object
If thermal fins are eliminated, then weight is reduced, but heat transfer efficiency may worsen
Solution Approach 1:
The battery cell casings serve their own thermal management needs by acting as the heat dissipation surfaces. Instead of requiring external thermal fins to attach to the cells, the casings themselves become the thermal interface with the heat exchanger plates, allowing the cells to self-manage their heat transfer without additional components.
Solution Approach 2:
The battery cell casing acts as an intermediary between the battery cell and the heat exchanger plate. The casing's external surface provides the thermal interface, mediating heat transfer from the cell interior through the casing wall to the heat exchanger, thereby maintaining effective heat transfer pathways without requiring thermal fins.
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 heat management without thermal fins, reducing weight, cost, and packaging size while maintaining efficient heat transfer, thereby improving battery cell capacity and life.
Implementation Method 1
at least one surface of the battery cell is exposed by the array frame and is contiguous with the heat dissipating structure
Implementation Method 2
the heat dissipating structure is a heat exchanger plate
Implementation Method 3
the heat dissipating structure is a thermal interface material (TIM)... the TIM is disposed between the surface of the battery cell and a heat exchanger plate
Data Source
AI summary
A battery pack includes a heat dissipating structure, an array frame positioned against the heat dissipating structure, and a battery cell retained by the array frame and arranged so at least one surface of the battery cell is exposed by the array frame and is contiguous with the heat dissipating structure. The heat dissipating structure may be a heat exchanger plate or a thermal interface material (TIM).