EV Battery Cooling Tube Layout for Controlled Gap Filler Thickness
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Solution Overview
Problem
Current battery cooling apparatuses for electric vehicles using a cooling fluid face inefficiencies due to excessive use of thermal interface materials (TIM) and the need for separate structures to maintain constant thickness, leading to increased weight and potential misalignment issues.
Innovation Solution
The proposed solution involves a heat insulator with an upper open part and an inner inclined surface, a tube accommodation part, and a gap filler application space, allowing for precise application and curing of the gap filler between the tube and the battery cell, along with a compression material to absorb assembly deviations and a condensed water passage for efficient water discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat surface of the tube is required when TIM is used, then surface adhesion is improved, but the area of TIM is increased more than necessary, leading to increased weight
Solution Approach 1:
The tube upper surface is changed from a flat surface to a curved surface with a specific radius of curvature. This curvature allows the TIM to be applied more efficiently, reducing the spread area while maintaining adequate contact and adhesion between the tube and battery cell, thereby reducing TIM weight without compromising thermal interface performance
2Strength
If gap filler is applied, then surface adhesion is improved, but a separate spread plate is required, leading to increased device complexity and risk of excessive filler usage
Solution Approach 1:
The spread plate function is merged into the insulator structure by forming a recessed portion directly on the insulator surface. This integration eliminates the need for a separate spread plate component, simplifying the overall structure while still providing the necessary function to control gap filler distribution and thickness during assembly
Solution Approach 2:
The recessed portion of the insulator serves as an intermediary structure that controls the gap filler application. It provides a defined space that guides the gap filler to the correct location and maintains proper thickness, preventing both insufficient and excessive filler application without requiring additional active components
3Strength
If elastic support is used to maintain constant thickness, then surface adhesion is improved, but when gap filler is applied, the elastic support cannot be maintained in constant thickness, requiring separate configuration
Solution Approach 1:
The insulator structure is segmented into different functional zones: a recessed portion for gap filler application and a compression member application portion for elastic support placement. This segmentation allows each component to perform its specific function effectively - the recessed portion controls gap filler thickness while the compression member maintains constant pressure and thickness, eliminating the conflict between these requirements
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 configuration enhances surface adhesion between the tube and the battery cell, reduces unnecessary material usage, maintains a constant gap filler thickness, and effectively manages condensed water, thereby improving cooling efficiency and reducing the overall weight and complexity of the cooling apparatus.
Implementation Method 1
a gap filler disposed in a space between an upper surface of the tube and the battery cell
Implementation Method 2
an insulator that insulates the tube 10 below the battery cell 30 from external elements
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~6
AI summary
Disclosed are battery cooling apparatus for electric vehicle, method of manufacturing, and an insulator structure for the apparatus including an insulator having a side wall of the insulator define an upper open part, a tube inserted into the upper open part of the insulator, and a gap filler disposed in a space between an upper surface of the tube and the battery cell, wherein the side wall comprises an inner inclined surface inclined inward and a tube accommodation part formed in an inner surface of the side wall to accommodate an outer part of the tube, and a gap filler application space is formed between the battery cell and the tube, when the tube is inserted between the tube accommodation part of the insulator and an inner bottom surface of the insulator, and a top of the side wall being located higher than the upper surface of the tube.