Battery Cooling Plate Mechanical Interlock Thermal Resistance
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Solution Overview
Problem
Existing battery cooling methods face challenges such as high costs, increased space and weight, and high tolerance requirements due to issues with thermal contact resistance, thermal constriction resistance, and mechanical aspects in maintaining contact between battery cells and cooling plates, especially in automotive applications.
Innovation Solution
A heat exchanger and battery unit structure with a mechanical interlock system using engaging devices such as recessed openings and protruding members to securely lock battery units to a heat exchanger plate, minimizing thermal resistance and constriction resistance, and allowing for efficient heat transfer through a fluid channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a chilled surface is pressed against battery cell surfaces to cool them, then cooling effectiveness is improved, but thermal contact resistance and thermal constriction resistance increase, and mechanical aspects of maintaining sufficient contact become problematic
Solution Approach 1:
The cooling system is segmented into multiple heat exchanger plates, each serving specific battery cells. The plates are divided into modular units that can be independently positioned and secured, allowing for better thermal contact distribution across the battery pack while reducing overall thermal resistance through parallel heat transfer paths.
Solution Approach 2:
The engagement mechanism transitions from simple surface contact to a three-dimensional interlocking system. Protruding members extend from the heat exchanger plates and engage with corresponding recesses in the battery cell housings, creating mechanical bonds in the vertical dimension that supplement the horizontal thermal contact, thereby ensuring reliable thermal coupling under vibration and thermal expansion conditions.
2Ease of manufacture
If battery units are spaced apart to allow circulating air cooling, then ease of manufacture is improved, but cooling effectiveness decreases and space allowances increase
Solution Approach 1:
Heat exchanger plates serve as intermediary components between battery cells and the cooling system. These plates provide structured thermal contact surfaces that facilitate heat transfer without requiring direct battery-to-battery spacing, allowing cells to be positioned closer together while maintaining effective cooling through the intermediary heat exchanger interface.
3Reliability
If conformal contact surfaces are used between battery units and cooling plates, then thermal contact is improved, but manufacturing precision requirements increase and device complexity increases
Solution Approach 1:
The engagement system incorporates mechanical flexibility through the interaction of protruding and recessed members, allowing for dynamic adjustment to manufacturing tolerances. The mechanical interlock accommodates variations in surface flatness and positioning accuracy while maintaining sufficient thermal contact pressure, eliminating the need for highly precise conformal surfaces.
4Temperature
If traditional cooling methods are used, then cooling function is provided, but space and weight penalties increase
Solution Approach 1:
The heat exchanger plates perform multiple functions simultaneously: they provide thermal contact for cooling, serve as structural support elements through their engagement mechanism, and act as mounting surfaces for electrical components. This multi-functionality consolidates what would otherwise require separate cooling plates, support structures, and mounting hardware, thereby reducing overall system weight.
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 mechanical interlock system provides improved temperature control, reduced thermal resistance, and increased efficiency in cooling battery units, addressing the limitations of existing methods by ensuring consistent contact and pressure between battery units and the heat exchanger, while reducing the need for conformal contact surfaces and minimizing space and weight penalties.
Implementation Method 1
heat to be dissipated or transported from (or to) the exterior surfaces of the battery housing by pressing a chilled (or heated) surface, whether it be a fluid-carrying heat exchanger cooling plate
Implementation Method 2
heat exchanger plate having spaced-apart first and second walls defining a fluid channel therebetween, the heat exchanger plate having a fluid inlet and a fluid outlet in communication with said fluid channel
Data Source
AI summary
A heat exchanger and battery unit structure is provided for cooling battery units (or cells) where the thermally conductive nature of the battery forms a cooling path. The heat exchanger is in the form of a cooling element provided with an engaging device formed on or attached to an outer surface of the cooling plate for receiving a battery unit (or cell). The interconnection between the battery unit (or cell) and heat exchanger creates a mechanical interlock between the two components that results in improved heat transfer properties between the two components.