Battery Pack Cooling Ribbon Assembly With Spacer Plate Isolation
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Solution Overview
Problem
Current thermal management systems for high-voltage battery packs in electric and hybrid vehicles are inadequate in efficiently regulating temperature, leading to heat-related degradation and reduced efficiency.
Innovation Solution
A cooling assembly comprising a manifold, ribbon headers, and ribbons with a spacer plate, where coolant flows through the system to cool cylindrical battery cells, with mechanical fasteners preventing force transfer during assembly and enhancing fluid communication and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat transfer fluid is circulated to and from fins or ribbons interspaced between the battery cells, then thermal management effectiveness is improved, but device complexity increases
Solution Approach 1:
The cooling system is divided into separate functional components: a manifold for fluid distribution, ribbon headers that connect to individual battery cell ribbons, and the ribbons themselves that contact the battery cells. This segmentation allows each component to be optimized independently and simplifies the overall system design and maintenance.
Solution Approach 2:
The patent introduces a spacer plate as an intermediary component between the manifold and the battery cells. This spacer plate provides a mounting surface for the ribbon headers and facilitates the connection of multiple ribbons to the coolant system, reducing the complexity of direct manifold-to-cell connections.
2Reliability
If multiple ribbons are connected to the manifold for cooling multiple battery cells, then thermal management coverage is improved, but assembly complexity increases
Solution Approach 1:
The ribbon header is designed as a universal component that can accommodate multiple ribbons and connect them to the coolant system. This multi-functional component simplifies assembly by providing a single connection point for multiple battery cell ribbons, reducing the number of separate connections required.
Solution Approach 2:
The ribbons are pre-connected to the ribbon headers before final assembly with the manifold. This preliminary action allows for easier handling and installation, as the ribbon-header assemblies can be prepared in advance and then quickly installed as complete units, reducing assembly complexity.
3Productivity
If the manifold is directly connected to the ribbon header, then fluid communication efficiency is improved, but structural integrity decreases due to force transfer
Solution Approach 1:
The spacer plate serves as a mechanical intermediary between the manifold and the ribbon header. It provides a rigid mounting surface that isolates the ribbon header from direct mechanical forces transmitted by the manifold, protecting the ribbons from damage while maintaining efficient fluid communication pathways.
Solution Approach 2:
The connection system is segmented into distinct mechanical and fluid communication functions. The spacer plate handles mechanical support and force isolation, while separate fluid passages maintain efficient coolant flow. This functional segmentation allows each aspect to be optimized without compromising the other.
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 cooling assembly effectively manages thermal conditions, preventing heat-induced degradation and improving the structural integrity and efficiency of battery packs by ensuring efficient coolant circulation and secure assembly.
Implementation Method 1
The coolant flows from the inlet line of the manifold to the ribbon feed line of the ribbon header to the outgoing channel of the ribbon to cool the cylindrical battery cell
Data Source
AI summary
A cooling assembly for a battery pack having at least one cylindrical battery cell includes a manifold having an inlet line for receiving a coolant and an outlet line for discharging the coolant, a ribbon header connected to the manifold and having a feed line in fluid communication with the inlet line and a return line in fluid communication with the outlet line, a ribbon in contact with the cylindrical battery cell and defining an outgoing channel and a return channel therethrough, wherein the ribbon is connected to the ribbon header and the outgoing channel is in fluid communication with the feed line and the return channel is in fluid communication with the return line, and a spacer plate disposed between the manifold and the ribbon header.