Vehicle Traction Battery Assembly with Offset Coolant Channels
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Solution Overview
Problem
Current thermal management systems for traction batteries in vehicles are inadequate in ensuring uniform temperature distribution and heat transfer across battery cells, which can impact performance and lifespan due to heat generation during charging and discharging.
Innovation Solution
A traction battery assembly design featuring a pair of endplates, side rails, and multiple coolant channels that span the longitudinal length of the battery cell array, with the coolant channels being in thermal communication with each battery cell to manage temperature and include a vent chamber for gas management, along with a busbar assembly for electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management systems are used for traction batteries, then the system structure is simple, but uniform temperature distribution and heat transfer across battery cells cannot be ensured
Solution Approach 1:
The coolant channel is divided into multiple segments including a first coolant channel spanning the longitudinal center, a second coolant channel at the lateral edge, and a third coolant channel at the distal end, each serving specific battery cell regions. This segmentation allows targeted thermal management for different battery cell zones, achieving uniform temperature distribution across all cells.
Solution Approach 2:
Different coolant channels are positioned to serve different local regions of the battery cell array. The first coolant channel serves central cells, the second coolant channel serves lateral edge cells, and the third coolant channel serves distal end cells. This local quality approach ensures each battery cell receives appropriate thermal management based on its specific thermal characteristics and position.
2Loss of energy
If multiple coolant channels are added to improve heat transfer, then thermal management performance improves, but device complexity increases
Solution Approach 1:
Multiple coolant channels (first, second, and third channels) are merged into a single integrated coolant distribution system that shares common coolant flow paths and connection points. The channels are interconnected through the battery assembly structure, allowing a single coolant loop to serve multiple cooling zones simultaneously, thereby improving heat transfer efficiency without proportionally increasing system complexity.
3Reliability
If coolant channels are positioned to cover all battery cell surfaces, then thermal communication with each cell is maximized, but manufacturing complexity increases
Solution Approach 1:
The coolant channels are designed to serve multiple functions simultaneously: the first coolant channel provides thermal management for central battery cells while also serving as a structural support element, the second coolant channel serves both cooling and sealing functions for lateral edge cells, and the third coolant channel provides thermal management for distal end cells while maintaining structural integrity. This multi-functionality reduces the need for separate components, simplifying manufacturing.
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
The design enhances thermal management by ensuring uniform fluid distribution and high heat transfer, maintaining optimal battery cell temperatures, thereby improving power output and extending battery life.
Implementation Method 1
The first coolant channel is in thermal communication with each battery cell along the upper face
Implementation Method 2
The first coolant channel spans a longitudinal length of the array and is offset from the longitudinal center axis
Data Source
AI summary
A traction battery assembly is provided. The traction battery assembly may include a battery cell array, a pair of endplates, and a first coolant channel. The battery cell array may define a longitudinal center axis along an upper face of the array. The pair of endplates may be configured to longitudinally retain the array therebetween. The first coolant channel may be in thermal communication with each battery cell along the upper face, span a longitudinal length of the array, and be offset from the longitudinal center axis. The assembly may include a second coolant channel in thermal communication with each battery cell, spanning the longitudinal length of the array, and covering a portion of the upper face of the array and a side face of the array. Each of the endplates may further define a plenum open to the first coolant channel and the second coolant channel.