Battery Module Compression Limiting Device for Thermal Interface

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Solution Overview

Problem

Existing battery pack designs face challenges in effectively managing thermal interface materials to prevent excessive wear and particle interference between battery cells and cooling plates, leading to inefficient heat transfer and potential damage.

Innovation Solution

A compression limiting device is introduced between the thermal interface pads and the cooling plate, formed from a rigid, thermally conductive, and electrically insulative material, which limits the compression of pads to prevent excessive wear and particle contact, ensuring optimal thermal contact and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If compressible pads are used to provide thermal contact between battery cells and cooling plate, then thermal conductivity is improved, but the pads experience excessive wear and particle interference over time

Engineering Contradiction:

Improvethermal conductivityVSAvoidpad wear resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

A compression limiting device is introduced as an intermediary component between the compressible pad and the cooling plate. This device prevents excessive compression of the pad while maintaining optimal thermal contact, thereby reducing wear and particle generation. The compression limiting device acts as a mediator that protects the pad from degradation while preserving the thermal conduction pathway.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The compression limiting device controls the compression parameter of the thermal interface pad, preventing it from exceeding optimal levels. By limiting the compression to a specific range, the pad maintains effective thermal contact without undergoing excessive deformation that leads to wear and particle generation. This parameter control extends the operational life of the pad.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If compression is increased to improve thermal contact, then heat transfer efficiency is improved, but particle interference and damage to battery cells increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidparticle interference

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The compression limiting device is pre-configured to prevent excessive compression before particles can be generated or interfere with battery cell operation. By establishing a mechanical limit on compression in advance, the system proactively prevents the harmful effects of over-compression, including particle generation and battery cell damage, while maintaining sufficient compression for effective heat transfer.

Inventive Principle:

Principle #9Preliminary anti-action

3Stability of the object's composition

If rigid material is used for compression limiting device, then structural stability is improved, but thermal conductivity may be reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidthermal conductivity

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The compression limiting device is made from composite material that combines rigid structural properties with adequate thermal conductivity. This composite construction allows the device to maintain structural stability for reliable compression limiting while simultaneously conducting heat effectively to maintain thermal management performance. The composite material resolves the contradiction between rigidity and thermal conductivity.

Inventive Principle:

Principle #40Composite materials

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 enhances thermal conductivity while preventing excessive compression and wear, maintaining the integrity of the battery cells and improving heat transfer efficiency, thereby extending the lifespan of the battery module.

Implementation Method 1

At least one compressible pad is arranged on the cooling plate. The at least one compressible pad has a first surface in contact with the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A compression limiting device is arranged adjacent to the at least one compressible pad. The compression limiting device has a first surface facing the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell

Methodology Applied

Scientific EffectMechanical compression: Compression

Data Source

PatentEP2845244B1Battery module with an enhanced thermal contact

Publication Date: 2017.03.15 BOSCH ROBERT BATTERY SYSTEMS LLC

AI summary

A battery module for enclosing at least one battery cell includes a cooling plate. At least one compressible pad is arranged on the cooling plate. The at least one compressible pad has a first surface in contact with the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell. A compression limiting device is arranged adjacent to the at least one compressible pad. The compression limiting device has a first surface facing the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell. A compressibility of the compression limiting device is less than a compressibility of the at least one compressible pad.