Battery Cooler Support Architecture Using Corrugated Beams
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Solution Overview
Problem
The existing battery cooler support architectures face challenges in maintaining intimate thermal contact with battery cells due to dimensional variations and functional limitations, leading to temperature uniformity issues and potential bending of the cooler, while also requiring weight savings in electric vehicles.
Innovation Solution
A battery cooler support architecture featuring a frame with parallel walls and a heat exchanger, along with support structures that engage the heat exchanger and extend between the walls to reduce stress on the cooler, and a beam structure that spans between module mounting rails to maintain uniform pressure and prevent bending, utilizing a corrugated beam design for enhanced flexural strength and weight efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a battery cooler is used to maintain temperature uniformity within 2°C to 5°C, then temperature control is improved, but the cooler is subject to bending and stress due to dimensional variations and functional limits
Solution Approach 1:
The patent changes the physical state and properties of the support structures by introducing corrugated beams with specific geometric parameters (wave height, wavelength, thickness) that transform the mechanical properties to provide both support and flexibility, resolving the contradiction between maintaining temperature uniformity and preventing cooler bending
Solution Approach 2:
The patent employs composite structural design by combining the cooler plate with corrugated support beams and rigid frame structures, creating a composite system where each component addresses specific requirements: the cooler provides thermal contact while the corrugated beams provide structural support with controlled flexibility
2Strength
If the cooler structure is reinforced to prevent bending, then structural integrity is improved, but weight increases which is undesirable in electric vehicles
Solution Approach 1:
The patent utilizes thin-walled corrugated beam structures that provide high strength-to-weight ratio. The corrugated geometry of the beams provides structural rigidity and bending resistance while maintaining thin profile and low weight, suitable for electric vehicle applications
Solution Approach 2:
The corrugated beam design introduces curvature in the form of waves and arches, which provides structural strength against bending loads while using minimal material. The curved geometry naturally resists bending forces without requiring heavy reinforcement
3Ease of manufacture
If dimensional variations of components are accommodated, then ease of assembly is improved, but temperature uniformity deteriorates
Solution Approach 1:
The patent introduces dynamic flexibility through the corrugated beam structures that can deform and adapt to dimensional variations in assembled components. The beams act as compliant elements that absorb dimensional tolerances while maintaining sufficient thermal contact pressure, resolving the contradiction between assembly ease and temperature uniformity
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 solution ensures consistent thermal contact and reduces stress on the cooler, maintaining the desired temperature uniformity of 2° C. to 5° C. while minimizing weight and preventing bending, thus enhancing the durability and efficiency of the battery cooling system.
Implementation Method 1
a heat exchanger positioned between the opposed parallel walls, the heat exchanger having a plate pair, the plate pair having a first plate and a second plate coupled to one another, the first plate and the second plate together defining a fluid flow channel permitting fluid flow from an inlet on the heat exchanger to an outlet on the heat exchanger
Implementation Method 2
a plurality of support structures engaging the heat exchanger and positioned between the opposed parallel walls, and extending from a first edge of the heat exchanger to a second end of the heat exchanger, wherein the first edge of the heat exchanger is proximate to one of the opposed parallel walls and the second edge of the heat exchanger is proximate to the other opposed parallel wall; the plurality of support structures engaging the one or more battery modules reducing stress on the heat exchanger
Data Source
AI summary
A battery cooler assembly having a frame with a pair of opposed parallel walls, with each wall having a ledge extending outwardly from the wall. A heat exchanger positioned between the walls, and having a plate pair together defining a fluid flow channel permitting fluid flow from an inlet to an outlet on the heat exchanger. One or more battery modules positioned on the heat exchanger. A plurality of support structures engage the heat exchanger and positioned between the walls; and extend from a first edge to a second end of the heat exchanger, where the first edge is proximate to one of the walls and the second edge is proximate to the other wall. The plurality of support structures engaging the one or more battery modules reducing stress on the heat exchanger.