Battery Pack Cooling Framework With Microchannels and Fewer Seals
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Solution Overview
Problem
Current thermal management systems for battery packs, such as those in electric vehicles, face challenges with non-uniform temperature profiles and leakage issues due to numerous seals and bulky polymer chassis, leading to reduced battery life and performance.
Innovation Solution
A thermal management system utilizing a framework with encapsulated graphite thermal conducting devices and microchannel structures to efficiently distribute heat across battery pouches, minimizing mass and maximizing thermal conductivity while reducing the need for bulky seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If individually formed microchannel cold flow plates connected to bulky polymer chassis are used, then thermal management coverage is improved, but device mass increases and leakage risk increases due to hundreds of seals
Solution Approach 1:
The patent merges the structural support function and thermal management function into a single integrated framework. The framework members serve both as structural supports and as carriers for microchannel heat exchangers, eliminating the separate bulky polymer chassis and reducing overall device mass while maintaining thermal management coverage.
Solution Approach 2:
The framework members are designed to perform multiple functions simultaneously: providing structural support for battery cells and serving as thermal management conduits through integrated microchannels. This multi-functionality reduces the number of separate components needed, thereby reducing mass and seal requirements.
2Temperature
If individually formed microchannel cold flow plates connected to bulky polymer chassis are used, then thermal management coverage is improved, but device mass increases and leakage risk increases due to hundreds of seals
Solution Approach 1:
The patent merges the structural support function and thermal management function into a single integrated framework. The framework members serve both as structural supports and as carriers for microchannel heat exchangers, eliminating the separate bulky polymer chassis and reducing overall device mass while maintaining thermal management coverage.
Solution Approach 2:
The patent extracts and eliminates the seal components from the system by redesigning the architecture. Instead of using multiple sealed connections between cold plates and polymer chassis, the integrated framework with internal microchannels removes the need for hundreds of seals, thereby eliminating the associated leakage risks.
3Temperature
If hundreds of seals are used in the battery pack, then thermal management coverage is improved, but reliability deteriorates due to leakage-prone connections
Solution Approach 1:
The patent extracts and eliminates the seal components from the system by redesigning the architecture. Instead of using multiple sealed connections between cold plates and polymer chassis, the integrated framework with internal microchannels removes the need for hundreds of seals, thereby eliminating the associated leakage risks.
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 system achieves uniform temperature distribution across battery cells, enhancing battery performance and longevity by effectively managing heat transfer with reduced mass and minimizing leakage risks.
Implementation Method 1
Each of the thermal conducting devices is a plate of encapsulated graphite having a first end coupled to the framework, and a second, opposite free end that is disposed between two of the battery pouches
Implementation Method 2
a first manifold to receive a working fluid... Each intermediate frame member includes a microchannel in fluid communication with the first manifold to receive the working fluid from the first manifold... a second manifold spaced from the first manifold and in fluid communication with the plurality of intermediate frame members to receive the working fluid from each microchannel
Data Source
AI summary
A device for removal of heat from a plurality of heat sources includes a first manifold to receive a working fluid, and a plurality of elongated intermediate frame members each in thermal communication with at least one of the plurality of heat sources. Each intermediate frame member includes a microchannel in fluid communication with the first manifold to receive the working fluid from the first manifold. Each elongated intermediate frame member includes a slot extending along a longitudinal axis of the heat transfer device. The device further includes a second manifold spaced from the first manifold and in fluid communication with the plurality of intermediate frame members to receive the working fluid from each microchannel in the plurality of intermediate frame members. The second manifold is configured to transfer the working fluid away from the plurality of heat sources.