Battery Cooling Plate with Opposing Flow for Thermal Homogenization
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Solution Overview
Problem
Existing cooling plate arrangements for battery systems fail to achieve uniform temperature distribution, leading to hotspots and increased risk of thermal runaway, and are not efficiently manufacturable or arrangeable for coolant flow.
Innovation Solution
A cooling plate arrangement featuring a corrugated intermediate sheet between two cover sheets, forming opposing flow direction cooling channels that enhance heat homogenization and reduce the risk of thermal runaway, while maintaining low space consumption and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional cooling plate arrangement is used, then the structure is simple and easy to manufacture, but uniform temperature distribution cannot be achieved leading to hotspots
Solution Approach 1:
The cooling plate is segmented into multiple cooling channels formed by corrugated intermediate sheets between cover sheets. This segmentation creates multiple flow paths that distribute coolant across different zones, enabling uniform temperature distribution while maintaining a modular structure that is relatively easy to manufacture.
Solution Approach 2:
The intermediate sheets are corrugated with curved profiles rather than being flat. This curvature creates alternating cooling channels that efficiently distribute coolant and heat, achieving uniform temperature distribution across the battery cells while the corrugated shape can be formed through standard sheet metal processes.
2Temperature
If cooling channels are added to achieve better heat dissipation, then temperature control improves, but space consumption increases
Solution Approach 1:
Multiple cooling channels are nested within each other between the cover sheets and corrugated intermediate sheets. This nested arrangement allows multiple cooling paths to occupy the same spatial envelope, achieving efficient heat dissipation without increasing the overall volume of the cooling plate assembly.
Solution Approach 2:
The cooling channels are arranged in alternating layers between the cover sheets, utilizing the vertical dimension rather than expanding horizontally. This dimensional arrangement enables efficient heat dissipation through multiple channels while maintaining a compact footprint with low space consumption.
3Reliability
If opposing flow direction channels are implemented, then thermal runaway risk is reduced through better heat homogenization, but manufacturing complexity increases
Solution Approach 1:
The cooling plate is segmented into multiple independent cooling channels with opposing flow directions using corrugated intermediate sheets. This segmentation allows coolant to flow in opposite directions through adjacent channels, creating heat homogenization that reduces thermal runaway risk, while each segment can be manufactured separately and assembled.
Solution Approach 2:
The corrugated profile of the intermediate sheets naturally creates opposing flow directions in adjacent channels through their curved geometry. This curvature-based design achieves thermal homogenization through opposing flows while using standard corrugated sheet manufacturing processes, avoiding complex custom tooling.
4Productivity
If multiple cooling channels are created, then coolant distribution improves, but device complexity increases
Solution Approach 1:
The cooling plate is divided into multiple cooling channels through corrugated intermediate sheets, allowing coolant to be distributed across multiple parallel paths. This segmentation improves coolant flow efficiency and heat dissipation productivity while maintaining a modular structure that is relatively simple to manufacture and assemble.
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 provides improved temperature homogenization and reduced risk of thermal runaway by efficiently distributing heat across battery cells, maintaining low space consumption and ease of manufacturing, and ensuring effective coolant flow.
Implementation Method 1
to provide thermal control of the battery pack a thermal management system is required to safely use the at least one battery module by efficiently emitting, discharging and/or dissipating heat generated from its rechargeable batteries
Implementation Method 2
the intermediate sheet and the first cover sheet form at least one first cooling channel confined between the intermediate sheet and the first cover sheet, the intermediate sheet and the second cover sheet form at least one second cooling channel
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present disclosure refers to a cooling plate arrangement (10) for cooling a plurality of battery cells (120) of a battery system (100), the cooling plate arrangement (10) comprises a first cover sheet (11), a second cover sheet (12), and a corrugated intermediate sheet (13) arranged between the first cover sheet (11) and the second cover sheet (12), wherein the intermediate sheet (13) and the first cover sheet (11) form at least one first cooling channel (14, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6) confined between the intermediate sheet (13) and the first cover sheet (11), the intermediate sheet (13) and the second cover sheet (12) form at least one second cooling channel (15) confined between the intermediate sheet (13) and the second cover sheet (12), and wherein the first cooling channel (14, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6) and the second cooling channel (15) are fluidly connected to each other so that first cooling channel (14, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6) and second cooling channel (15) comprise an opposite flow direction (F1, F2).