EV Battery Stack Cooling Panels Under Compression Pressure
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Solution Overview
Problem
Electric vehicles face challenges in maintaining optimal temperature control of lithium ion battery cells, leading to performance degradation, efficiency loss, and reduced battery life due to uneven temperature distribution and pressure variations.
Innovation Solution
A thermal management system with interleaved thermal control panels and a pressurized fluid circulation system that maintains uniform temperature and pressure distribution across battery cells, using flexible, lightweight panels and a pump to circulate thermal transfer fluid through channels to manage heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid cooling plates are used to maintain structural integrity under compression, then strength is improved, but weight increases and flexibility decreases
Solution Approach 1:
The patent uses flexible cooling panels with thin-walled fluid channels instead of rigid cooling plates. These panels can deform under compression forces from battery expansion while maintaining fluid flow channels, achieving both weight reduction and structural adaptability. The flexible panels conform to battery shape changes without requiring heavy reinforcement structures.
2Weight of moving object
If thermal panels are made thin and flexible for weight reduction, then weight is improved, but resistance to compression-induced collapse worsens
Solution Approach 1:
The patent applies retention elements (such as springs or pre-compressed mechanical structures) that exert a counteracting force to balance the compression forces from battery expansion. This allows thin, lightweight thermal panels to maintain their shape and prevent fluid channel collapse without requiring thick, heavy walls. The retention elements provide the necessary structural support dynamically.
3Temperature
If uniform pressure is applied to maintain thermal contact, then heat transfer efficiency is improved, but battery cell deformation increases
Solution Approach 1:
The patent employs dynamic retention elements that can adjust their compressive force in response to battery cell expansion and contraction during charging cycles. This dynamic adjustment maintains optimal thermal contact pressure without applying excessive static force that would cause permanent deformation. The system adapts to changing battery dimensions while preserving cell integrity.
4Temperature
If fluid channels are made small for efficient heat transfer, then heat transfer efficiency is improved, but susceptibility to collapse under pressure increases
Solution Approach 1:
The patent uses flexible panel structures with integrated fluid channels where the panel material itself provides structural support to the channels. The flexible nature allows the channels to maintain their shape under compression without requiring excessive wall thickness, preserving both heat transfer efficiency and collapse resistance through material properties rather than geometric reinforcement.
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 effectively maintains battery cells within a desired temperature range, enhancing performance and extending battery life by preventing delamination and ensuring efficient heat transfer.
Implementation Method 1
the pump to create a fluid pressure within the at least one fluid channel of each thermal panel that is greater than or equal to the stack pressure
Implementation Method 2
the thermal transfer fluid supports the at least one fluid channel of each thermal panel to inhibit collapse
Implementation Method 3
efficient heat transfer
Implementation Method 4
A pump circulates a thermal transfer fluid through the at least one fluid channel
Implementation Method 5
At least one retention element applies a retention pressure to the battery stack to compress the plurality of battery cells and plurality of thermal panels
Data Source
AI summary
An electric vehicle including a battery including a plurality of battery cells and a plurality of thermal control panels interleaved with the plurality of battery cells to form a battery stack, each thermal control panel including walls defining at least one fluid channel. At least one retention element applies a retention pressure to the battery stack to compress the plurality of battery cells and plurality of thermal control panels of the battery stack, the walls of the thermal panels being under compression by a stack pressure including at least the retention pressure. A pump circulates a thermal transfer fluid through the at least one fluid channel of each thermal panel, the pump to create a fluid pressure within the at least one fluid channel of each thermal panel that is greater than or equal to the stack pressure.