Battery Cooling Device Deformation Control Using Foam Support

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Solution Overview

Problem

Existing battery housing designs face challenges in efficiently linking battery modules to cooling devices due to deformation issues caused by high compressive forces required for heat dissipation, leading to uneven heat transfer and potential damage to components.

Innovation Solution

A method involving a battery housing arrangement with a cooling device and an underride guard, where a foam-like material is used to support the cooling device and apply a supporting force, reducing deformation and allowing for more efficient thermal linking between the battery module and cooling device, thereby minimizing gap widths and enhancing heat dissipation while increasing crash safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a viscous heat conducting element is inserted between the battery module and cooling device, then heat transfer efficiency is improved, but the cooling device deforms due to high compressive forces

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidcooling device deformation

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

The foam-like material is inserted into the gap between the cooling device and underride guard before the viscous heat conducting element is applied. This preliminary action provides structural support to the cooling device, preventing deformation when compressive forces are later applied during module insertion.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The foam-like material acts as an intermediary support structure between the cooling device and underride guard. It provides mechanical support to prevent cooling device deformation while allowing the viscous heat conducting element to fulfill its thermal linkage function without causing damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If high compressive force is applied to distribute heat conducting material, then heat dissipation efficiency is improved, but damage to battery modules and cooling device occurs

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcomponent damage

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The foam-like material is installed in advance to provide structural support before the high compressive force is applied. This preliminary reinforcement prevents damage to battery modules and cooling device during the heat conducting material distribution process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The foam-like material serves as a cushioning element that absorbs and distributes the high compressive forces applied during heat conducting material installation. This beforehand cushioning prevents damage to the cooling device and battery modules while still allowing effective heat dissipation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If the cooling device is deformed, then assembly is simplified, but heat transfer becomes uneven and gap widths increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidheat transfer uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The foam-like material is installed beforehand to maintain the cooling device's structural integrity and flatness during assembly. This prevents deformation that would lead to uneven heat transfer and excessive gap widths, while still allowing for simplified assembly procedures.

Inventive Principle:

Principle #10Preliminary action

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 approach reduces the deformation of the cooling device, minimizes the amount of viscous heat conducting material needed, enhances heat transfer efficiency, and provides increased crash safety by distributing impact forces effectively, resulting in improved thermal performance and cost savings.

Implementation Method 1

a foam-like material, which cures hard, is at least partially inserted into the gap between the cooling device and the underride guard and at least temporarily applies a supporting force onto the cooling device in the direction of the cooling device

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a viscous heat conducting element is placed into the holding section such that the heat conducting element is located between an underside of the battery module that faces the cooling device and the cooling device

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11489216B2Method for providing a battery arrangement for a motor vehicle, and motor vehicle

Publication Date: 2022.11.01 AUDI AG

AI summary

A method for providing a battery arrangement for a motor vehicle, wherein a battery housing arrangement is provided, including a battery housing having at least one holding section for holding a battery module, a cooling device which provides at least part of a housing floor of the battery housing, and an underride guard which is disposed outside the battery housing at the cooling device such that a gap is created between the cooling device and the underride guard, and a viscous heat conducting element and a battery module are placed inside the holding section such that the heat conducting element is located between the underside of the battery module, which faces the cooling device, and the cooling device.