Battery Assembly Sidewall Flanges for Thermal Contact
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Solution Overview
Problem
Conventional battery assemblies for electrified vehicles face challenges in achieving optimal thermal performance due to inadequate contact and heat management between battery cells and cold plates, leading to inefficient heat dissipation.
Innovation Solution
The battery assembly incorporates a support structure with sidewalls that extend beyond the battery cells, attaching to either a cold plate or tray, using flanges and fastening techniques to ensure consistent contact and improved thermal interface, potentially incorporating thermal interface materials for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional battery assemblies use simple support structures without extended sidewalls, then the device complexity is reduced, but thermal performance deteriorates due to inadequate contact between battery cells and cold plate
Solution Approach 1:
The sidewall is segmented into multiple functional flanges: a first flange that contacts the battery cell and a second flange that extends to contact the cold plate. This segmentation allows each flange to perform a specific thermal management function, improving overall thermal performance while maintaining a manageable structural complexity
Solution Approach 2:
The sidewall structure is extended in the vertical dimension beyond the battery cell height, creating a multi-level contact system. The first flange operates at the battery cell level while the second flange operates at the cold plate level, utilizing vertical space to improve thermal contact without increasing horizontal footprint
2Reliability
If sidewalls are extended beyond battery cells to attach to cold plate, then thermal contact is improved, but manufacturing complexity increases due to additional flanges and attachment requirements
Solution Approach 1:
The support structure integrates multiple functions into a single sidewall component: structural support, thermal conduction path, and mechanical attachment to the cold plate. By combining these functions into one integrated sidewall with flanges, the design improves contact consistency while avoiding the need for separate components, thereby managing manufacturing complexity
3Temperature
If flanges are used to attach sidewall to cold plate, then thermal interface is improved, but device complexity increases due to additional components and fastening mechanisms
Solution Approach 1:
The flange structure serves multiple purposes simultaneously: it provides a mounting surface for attaching the sidewall to the cold plate, creates a compressed thermal interface, and structurally reinforces the connection. This multi-functionality improves thermal interface efficiency while avoiding the need for additional dedicated fastening components, thereby managing device complexity
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 configuration enhances thermal performance by maintaining consistent contact between battery cells and the cold plate, facilitating effective heat removal and improving the overall efficiency of the battery assembly.
Implementation Method 1
a thermal interface material is compressed between the cold plate and the plurality of battery cells
Implementation Method 2
maintaining consistent contact between the battery cells and the cold plate, facilitating effective heat removal
Data Source
AI summary
A battery assembly includes a plurality of battery cells and a support structure positioned about the plurality of battery cells. The support structure includes at least one sidewall and the at least one sidewall includes a first flange that extends adjacent a top surface of each of the plurality of battery cells and a second flange that extends beyond a bottom surface of each of the plurality of battery cells.