Battery Cooling Plate with Nested U-Shaped Channels
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Solution Overview
Problem
Battery cooling plates with large channel geometries are prone to deformation during assembly line vacuum and fill processes, and tend to trap air bubbles due to their design.
Innovation Solution
A battery cooling plate design featuring a serpentine shaped cooling flow path with multiple narrow channels and lands, and nested U-shaped channels to prevent deformation and air entrapment, with channel widths ranging from 0.05 mm to less than 6 mm, and substrates made from materials like aluminum or high thermal conductivity polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If large channel geometry is used in battery cooling plate, then coolant flow capacity is improved, but structural stability during assembly deteriorates
Solution Approach 1:
The cooling plate is divided into multiple cooling segments (at least six segments) separated by reinforcing lands. Each segment contains cooling channels, and the lands between segments provide structural reinforcement that prevents deformation during vacuum and fill processes while maintaining adequate coolant flow capacity through the distributed channel network.
Solution Approach 2:
The cooling channels have non-uniform geometry with varying widths along their length. The channel width transitions from wider regions (providing better coolant flow capacity) to narrower regions (providing structural reinforcement). Specifically, channel width varies from about 0.05 mm to less than 6 mm, with narrowest regions at segment boundaries and widest regions in cooling segment centers.
2Quantity of substance
If large channel geometry is used in battery cooling plate, then coolant flow capacity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The cooling plate is divided into multiple cooling segments (at least six segments) separated by reinforcing lands. Each segment contains cooling channels, and the lands between segments provide structural reinforcement that prevents deformation during vacuum and fill processes while maintaining adequate coolant flow capacity through the distributed channel network.
Solution Approach 2:
The cooling channels have non-uniform geometry with varying widths along their length. The channel width transitions from wider regions (providing better coolant flow capacity) to narrower regions (providing structural reinforcement). Specifically, channel width varies from about 0.05 mm to less than 6 mm, with narrowest regions at segment boundaries and widest regions in cooling segment centers.
3Area of stationary object
If serpentine cooling flow path is used, then cooling coverage is improved, but air entrapment increases
Solution Approach 1:
The cooling plate is divided into multiple cooling segments (at least six segments) separated by reinforcing lands. Each segment contains cooling channels, and the lands between segments provide structural reinforcement that prevents deformation during vacuum and fill processes while maintaining adequate coolant flow capacity through the distributed channel network.
Solution Approach 2:
The cooling channels have non-uniform geometry with varying widths along their length. The channel width transitions from wider regions (providing better coolant flow capacity) to narrower regions (providing structural reinforcement). Specifically, channel width varies from about 0.05 mm to less than 6 mm, with narrowest regions at segment boundaries and widest regions in cooling segment centers.
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 design enhances the structural integrity of the cooling plate under vacuum and filling operations, reducing the likelihood of air entrapment and ensuring efficient coolant distribution, thereby maintaining performance and preventing deformation.
Implementation Method 1
a battery cooling plate having a serpentine shaped cooling flow path formed therein
Implementation Method 2
cooling flow path including a first cooling segment and an adjacent upstream second cooling segment
Data Source
AI summary
One exemplary embodiment including a battery cooling plate has discrete channels. In one exemplary embodiment each of the channels has a width ranging from about 1 mm to about 5 mm. In another exemplary embodiment the battery cooling plate includes a first cooling channel having a flow path generally in a U shape, and a plurality of other channels each having a generally U-shaped flow path, and wherein the other flow channels are in a nested position with respect to the first flow channel. In another exemplary embodiment the battery cooling plate a battery cooling plate includes a serpentine shaped cooling flow path formed therein, the cooling flow path including a first cooling segment and an adjacent upstream second cooling segment, wherein the second cooling segment includes at least a first cooling channel and a second cooling channel and at least a first land interposed between the first cooling channel and second cooling channel, and wherein the second cooling segment has at least one more land and one more channel than the first cooling segment.