Integrated Battery Base Cooling Ducts for Uniform Cell Temperatures
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Solution Overview
Problem
Existing battery designs suffer from thermal gradients between cells due to non-uniform heat transfer, leading to premature cell failure and increased weight and cost from separate heat transfer circuits and thermal interfaces.
Innovation Solution
A battery support with integrated E- or W-shaped heat transfer ducts sharing a common wall, laser-welded to the base, reduces thermal gradients and weight by eliminating unnecessary walls and interfaces, using materials like titanium for mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a heat transfer circuit with separate base and circuit components is used, then ease of manufacture and maintenance is improved, but weight increases and thermal interface complexity increases
Solution Approach 1:
The heat transfer circuit is integrated directly into the base structure, merging two previously separate components (base and heat transfer circuit) into a single unified structure. This eliminates the need for separate thermal interface materials and reduces the total number of parts, thereby reducing weight while maintaining ease of manufacture through a consolidated component.
2Ease of operation
If tubes are connected in parallel for heat transfer, then flow distribution is improved, but thermal gradient between inlet and outlet increases
Solution Approach 1:
The heat transfer circuit transitions from a one-dimensional linear tube configuration to a two-dimensional planar network embedded in the base. This dimensional change allows heat transfer fluid to flow through multiple parallel pathways simultaneously, improving flow distribution while maintaining more uniform temperature across the base surface by distributing thermal load across multiple zones.
Solution Approach 2:
The heat transfer circuit is divided into multiple discrete ducts or channels within the base, each handling a portion of the thermal load. This segmentation allows independent flow paths that can be optimized for uniform heat distribution, reducing thermal gradients between different regions of the battery assembly.
3Ease of repair
If heat transfer circuit is independent of base, then maintenance is improved, but number of parts and thermal interface complexity increases
Solution Approach 1:
The heat transfer circuit is merged with the base structure, creating a single integrated component rather than separate parts. This reduces the number of parts and eliminates thermal interface materials, while maintenance can still be performed by accessing the integrated circuit through the battery assembly without requiring separation of base and circuit components.
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
Homogenizes cell temperatures, reduces weight and thermal inertia, and lowers manufacturing costs by integrating the heat transfer circuit directly onto the base, enhancing thermal management efficiency.
Implementation Method 1
heat transfer circuit is in contact with the base and is in the form of a set of welded tubes
Implementation Method 2
a heat transfer liquid circulates
Implementation Method 3
The heat transfer liquid may be selected from a refrigerant, glycol water, or a gas, in particular air
Implementation Method 4
laser welding of the walls of the heat transfer circuit and the base is performed
Data Source
AI summary
Battery support comprising a base and a heat transfer circuit, the heat transfer circuit comprising a first duct and a second duct, a first end of the first duct allowing a heat transfer liquid to be received, a first end of the second duct allowing said heat transfer liquid to be discharged, the first duct and the second duct being connected together by the second end thereof, the first duct and the second duct being delimited on the one hand by the base and on the other hand by a set of walls, the first duct and the second duct sharing a common wall.