Extruded Battery Cold Plate With PCM Cavities for Low-Cost Thermal Control
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Solution Overview
Problem
Existing thermal management systems for batteries in hybrid or electric vehicles face challenges in achieving robustness and low manufacturing costs while ensuring effective temperature regulation, particularly due to the complexity and cost of forming fluid circuits and encapsulating Phase Change Materials (PCMs).
Innovation Solution
A thermal management device comprising an extruded plate with integrated channels and encapsulation cavities for PCMs, connected by a diverting cap to allow coolant flow, and sealed using plugs with recesses for adhesive bonding, facilitating a simple and cost-effective manufacturing process suitable for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extruded plates with integrated fluid circuits and PCM cavities are used, then thermal management effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The device is divided into separate functional components: an extruded plate with integrated channels and cavities, a diverting cap with plugs, and sealing elements. This segmentation allows each component to be manufactured using optimized processes (extrusion for the plate, casting for the cap) and then assembled, reducing overall manufacturing complexity while maintaining thermal management effectiveness.
Solution Approach 2:
The extruded plate integrates multiple functions into a single component: fluid channels for coolant flow, encapsulation cavities for PCM, and structural support. This merging of functions reduces the number of separate parts needed, simplifying the overall device structure and assembly process while ensuring effective thermal management.
2Manufacturing precision
If traditional machining methods are used for fluid circuits and PCM cavities, then manufacturing precision is improved, but manufacturing cost and time increase
Solution Approach 1:
Traditional mechanical machining operations are replaced with extrusion and casting processes. The extruded plate is formed by extruding material through a die that defines the channel and cavity geometry, while the diverting cap is cast with integrated plugs. These processes achieve the required precision without the high costs and long cycle times associated with machining, making the device suitable for mass production.
3Reliability
If robust sealing and connection methods are used, then reliability is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The plugs are inserted into recesses in the diverting cap, creating a nested structure where one component fits into another. This nesting provides inherent mechanical retention and sealing surfaces, ensuring reliable connections without requiring additional fasteners, seals, or complex assembly steps. The plugs are simply inserted into the recesses, and the geometry itself provides the sealing and retention function.
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 solution provides a robust and cost-effective thermal management system that maintains battery temperature within an optimal range, ensuring efficient thermal regulation and compatibility with industrial manufacturing rates, while being resistant to mechanical and thermal stresses.
Implementation Method 1
When the temperature reaches this melting point, the PCM materials absorbs thermal energy thanks to the phase change and thus ensures temperature stability for the Battery cells
Implementation Method 2
the use of Phase Change Materials (PCM) is added into the cooling device. These materials have a relatively low melting point. When the temperature reaches this melting point, the PCM materials absorbs thermal energy thanks to the phase change
Implementation Method 3
extruded plates, also called cold extruded plates, or cold plates made of brazed sheets through which a coolant can circulate
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3~4
AI summary
An object of the invention is a thermal management device (1) for a battery, including an extruded plate (2). The extruded plate (2) comprises a first channel (13) and a second channel (23), configured to allow a flow of a coolant. The extruded plate (2) also includes at least one encapsulation cavity (33), intended to be filled by a Phase Change Material. The first channel, the second channel and the encapsulation cavity extend between a front face (10) and a rear face (20) of the extruded plate (2). The device comprises an inlet/outlet cap (40), connected to the front face (10) and a diverting cap (50,50'), connected to the rear face (20). Both caps provide plugs of each encapsulation cavity. The diverting cap forms a connecting channel (52i, 52s), connecting the first channel (13) to the second channel (23).