Battery Cooling Module Foot Profile Design for Jointless Interface
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Solution Overview
Problem
Conventional battery cooling systems for lithium-ion batteries face challenges in joint durability, thermal conductivity, and manufacturing complexity due to the use of filler materials and hot joining methods like brazing or welding.
Innovation Solution
A battery cooling system comprising a cooling plate and a heat sink with modules under compressive load, eliminating the need for filler materials and simplifying the manufacturing process by securing the cooling plate to the heat sink through friction forces, allowing for efficient thermal conductivity without additional joining materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot joining methods (brazing or welding) are used to connect cooling fins to heat sink, then joint strength is improved, but material microstructure is adversely affected and joint durability deteriorates
Solution Approach 1:
The patent replaces hot joining methods (brazing/welding) with a mechanical compression system. Cooling fins are compressed against the heat sink surface using compression elements that apply continuous mechanical pressure, eliminating the need for thermal joining processes that damage material microstructure while maintaining secure mechanical and thermal connection.
Solution Approach 2:
The patent introduces compression elements as intermediary components between the cooling fins and heat sink. These compression elements transmit and distribute compressive forces uniformly across the interface, enabling secure mechanical attachment without direct hot joining of the cooling fin to the heat sink, thereby preserving material integrity.
2Ease of manufacture
If filler materials (brazing solders, welding consumables, bonding adhesives) are used in joining processes, then joint formation is facilitated, but thermal conductivity deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent extracts and eliminates filler materials from the joining process. By using direct compression between cooling fins and heat sink, the system achieves secure mechanical and thermal connection without requiring any intermediate filler materials, thereby maintaining optimal thermal conductivity pathways.
Solution Approach 2:
The patent replaces chemical/adhesive joining systems with a pure mechanical compression system. The compression elements apply sustained mechanical pressure to maintain intimate contact between cooling fins and heat sink, eliminating the need for bonding adhesives or other filler materials that would impede thermal conduction.
3Stability of the object's composition
If conventional hot joining methods are used, then permanent joint formation is achieved, but manufacturing complexity increases due to additional materials and processes
Solution Approach 1:
The patent replaces complex hot joining processes (brazing, welding) with a simpler mechanical compression system. The compression elements provide continuous mechanical pressure to maintain joint stability, eliminating the need for complex thermal processes, filler materials, and associated manufacturing steps while achieving secure permanent attachment.
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 solution enhances joint durability, improves thermal conductivity between adjacent battery cells, and reduces manufacturing complexity, providing a more efficient and serviceable cooling system for lithium-ion batteries.
Implementation Method 1
facilitates a thermal conductivity from adjacent battery cells
Implementation Method 2
securing the cooling plate to the heat sink through friction forces
Data Source
AI summary
A cooling system for a battery cell includes a cooling plate and a heat sink. The heat sink has a pair of modules. An end of the cooling plate is constricted between the modules. The modules are placed under a compressive load to secure the cooling plate to the heat sink.