Battery Array Frame Standoff for Thermal Interface Material Reduction
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Solution Overview
Problem
Existing electrified vehicle battery packs require significant amounts of thermal interface material (TIM) to fill the gap between thermal fins and heat exchanger plates, which is costly and inefficient.
Innovation Solution
Incorporating an array frame standoff to control the gap between the thermal fin and the heat exchanger plate, reducing the need for TIM by allowing precise adjustment and minimizing the gap size, thereby optimizing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal interface material is used to fill the gap between thermal fins and heat exchanger plates, then thermal conductivity is improved, but the amount of TIM required increases cost and complexity
Solution Approach 1:
The patent introduces a TIM recess as an intermediary structural feature in the heat exchanger plate that pre-positiones and contains the thermal interface material. This mediator structure ensures optimal TIM placement between the thermal fin and heat exchanger plate, improving thermal conductivity while reducing overall TIM consumption by limiting it to only the necessary contact areas.
Solution Approach 2:
The patent changes the geometric parameters of the heat exchanger plate by incorporating recesses or cavities at the contact surfaces. This parameter modification allows the TIM to be contained within specific volumes, reducing the total amount of TIM needed while maintaining effective thermal contact between components.
2Reliability
If gap between thermal fin and heat exchanger plate is reduced, then thermal conductivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the heat exchanger plate during manufacturing. These recesses are created in advance to accommodate the TIM and establish the optimal gap geometry before assembly. This preliminary structuring eliminates the need for high-precision gap control during final assembly, as the recesses inherently define the correct spacing and contact areas.
Solution Approach 2:
The TIM recess acts as an intermediary structure that mediates the gap between the thermal fin and heat exchanger plate. By providing a pre-defined cavity for TIM placement, the recess serves as a buffer that accommodates manufacturing tolerances while ensuring consistent thermal contact, thereby reducing the stringency of gap control requirements.
3Ease of manufacture
If TIM amount is reduced, then cost is lowered, but thermal management effectiveness may be compromised
Solution Approach 1:
The patent changes the geometric parameters of the heat exchanger plate by incorporating recesses that concentrate TIM in high-value contact areas. This parameter modification redirects TIM from distributed low-impact regions to concentrated high-impact regions, maintaining thermal management effectiveness while reducing total TIM consumption and associated costs.
Solution Approach 2:
The patent applies local quality by creating localized recesses at specific contact points between thermal fins and the heat exchanger plate. This ensures that TIM is applied precisely where it is most needed for thermal transfer, rather than uniformly across entire surfaces. The localised approach maintains thermal management effectiveness in critical areas while reducing overall TIM usage.
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 reduces the amount of TIM required, simplifies assembly, and lowers costs while maintaining effective thermal management for battery performance.
Implementation Method 1
A standoff of the array frame establishes a gap between the heat exchanger plate and the thermal fin
Implementation Method 2
A thermal interface material (TIM) may also be used to increase the thermal conductivity between the battery cells and the heat exchanger plate
Data Source
AI summary
This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a heat exchanger plate and a battery array positioned against the heat exchanger plate. The battery array may include an array frame and a thermal fin held within the array frame. The array frame may additionally include a standoff for controlling a size of a gap extending between the thermal fin and the heat exchanger plate. By controlling this gap, the amount of thermal interface material (TIM) that must be utilized to fill the gap can be reduced.