Battery Cooling Body with Segmented Webs for Condensation Control
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Solution Overview
Problem
Existing battery heat sinks for vehicle batteries face challenges in reducing condensation formation and efficiently combining cooling, thermal insulation, and mechanical protection in a cost-effective and simple design.
Innovation Solution
A plate-shaped battery heat sink with internal channels for fluid cooling, where the protective surface is connected to the cooling surface only via webs, forming an air bridge for thermal insulation and using an air cushion to separate the channels from the protective surface, allowing efficient cooling and reduced condensation while providing mechanical protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the protective surface is directly connected to the cooling surface, then structural strength is improved, but condensation formation increases due to heat loss
Solution Approach 1:
The connection between the protective surface and cooling surface is segmented through the use of discrete webs instead of a continuous connection. These webs are spaced apart to create air cushions, breaking the thermal path while maintaining structural integrity. This segmentation reduces heat loss to the protective surface, thereby minimizing condensation formation.
Solution Approach 2:
An air cushion acts as an intermediary layer between the cooling surface and the protective surface. This air layer serves as a thermal insulator, mediating the heat transfer between the two surfaces. The air cushion reduces direct thermal contact, preventing excessive heat loss to the protective surface and thus reducing condensation.
2Object-affected harmful factors
If thermal insulation is added on the outside of the heat sink, then condensation formation is reduced, but device complexity increases
Solution Approach 1:
The protective surface and the cooling surface are merged into a single integrated component rather than separate parts. This integration eliminates the need for additional external thermal insulation layers, as the air cushions within the unified structure provide the necessary insulation. The design achieves both protection and thermal management in one component, reducing overall device complexity.
Solution Approach 2:
The protective surface serves multiple functions: it provides mechanical protection, acts as a thermal insulator through the air cushions, and maintains structural integrity. This multi-functionality eliminates the need for separate insulation components, simplifying the overall device design while effectively preventing condensation.
3Temperature
If the cooling surface is made larger to enhance cooling capacity, then heat dissipation is improved, but the risk of condensation on the protective surface increases
Solution Approach 1:
The thermal insulation properties are localized to specific areas where air cushions are created between the cooling surface and protective surface. This local quality approach ensures that heat is effectively managed at the cooling surface while the protective surface remains thermally isolated, preventing condensation in those specific regions without compromising overall cooling capacity.
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 design effectively reduces condensation on the heat sink, enhances cooling capacity, and integrates thermal insulation and protection in a single component, optimizing the heat transfer and mechanical protection of the battery system.
Implementation Method 1
the channels being separated by an air cushion from a protective surface (5) of the battery cooling body
Implementation Method 2
internal channels (3) for conducting a cooling fluid
Implementation Method 3
the battery cells being connected to a surface of the heat sink with good thermal conductivity, so that the heat of the cells is transferred to the heat sink
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A battery heat sink (1) for cooling battery cells (2) of a vehicle battery, wherein the battery heat sink (1) is plate-shaped and has internal channels (3) for guiding a cooling fluid, wherein the channels (3) are in good thermal conductivity in contact with a cooling surface (4) of the battery heat sink (1), wherein the battery cells (2) can be arranged on the cooling surface (4) when the battery heat sink (1) is installed, wherein the battery heat sink (1) has a protective surface (5), wherein the protective surface (5) forms the boundary of the battery heat sink (1) opposite the cooling surface (4), wherein the protective surface (5) is connected to the cooling surface (4) exclusively via webs (6), wherein the webs (6) are formed exclusively in areas of the heat sink (1) in which no channels (3) are formed.