Battery Cooling Envelope With Rigid Edge Support for Thermal Contact
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Solution Overview
Problem
Existing battery cooling systems face challenges in efficiently dissipating heat from central battery cells due to high thermal resistance and mechanical weaknesses in flexible casings, leading to increased costs and reduced thermal efficiency.
Innovation Solution
A cooling device with a flexible casing and a rigid support structure that encloses lateral edges, allowing for improved mechanical strength and thermal contact, suitable for vertical or suspended positions, and includes snap-fit assembly for easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a flexible casing is used for cooling device, then thermal contact with battery elements is improved and manufacturing simplicity is enhanced, but mechanical strength and resistance to internal fluid flow pressure are insufficient
Solution Approach 1:
The cooling device combines a flexible casing made of elastomeric material with an internal rigid support structure. This composite construction allows the outer flexible layer to maintain thermal contact with battery elements while the internal rigid structure provides mechanical strength to resist internal fluid flow pressure and maintain structural integrity.
2Temperature
If thermal interface materials are used between cooling device and battery cells, then thermal exchange resistance is improved, but cost and mass of the battery significantly increase
Solution Approach 1:
The patent uses a flexible casing made of thin elastomeric material that directly contacts the battery elements. This flexible shell provides sufficient thermal contact without requiring additional thermal interface materials, thereby avoiding the increased mass and cost associated with traditional thermal interface materials while maintaining effective heat transfer.
3Ease of manufacture
If a flexible envelope is used instead of rigid structure, then thermal contact and manufacturing simplicity are improved, but the device cannot be placed in vertical or suspended position due to low mechanical resistance
Solution Approach 1:
The cooling device combines a flexible casing made of elastomeric material with an internal rigid support structure. This composite construction allows the outer flexible layer to maintain thermal contact with battery elements while the internal rigid structure provides mechanical strength to resist internal fluid flow pressure and maintain structural integrity.
4Temperature
If areas of the casing not positioned against rigid elements are used, then flexibility and thermal contact are maintained, but these areas wear and deform over time under internal fluid flow pressure
Solution Approach 1:
The cooling device combines a flexible casing made of elastomeric material with an internal rigid support structure. This composite construction allows the outer flexible layer to maintain thermal contact with battery elements while the internal rigid structure provides mechanical strength to resist internal fluid flow pressure and maintain structural integrity.
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 enhanced thermal contact and mechanical stability, enabling efficient heat dissipation while maintaining a lightweight and cost-effective design, suitable for various battery configurations.
Implementation Method 1
circulating a cooling fluid (usually a water-glycol mixture) through a cooling unit located beneath the battery cells. The fluid acts as a heat transfer fluid, removing thermal energy from the battery and discharging it outside the enclosure as it circulates.
Implementation Method 2
heat dissipation is highly dependent on the thermal resistance of exchange between the electrical connectors or the underside of the battery elements as appropriate, on the one hand, and the cooling device on the other
Implementation Method 3
the said flexible envelope deforming freely under the effect of the circulation pressure of the heat transfer fluid and thus conforming to the contours of the lower surface of the battery elements or electrical connectors, thereby providing good thermal contact
Data Source
Figure 1
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Figure 4~5
AI summary
Cooling device (30) for an electric battery (10), the cooling device (30) comprising: - a casing (32) formed of two sheets (36) of flexible material extending opposite each other, the casing (32) defining lateral edges (47), - at least one fluid circulation conduit (52) extending between the sheets (36), and - at least one inlet fluid connector (50) and at least one outlet fluid connector (50). The cooling device (30) further includes: - a rigid support structure (34), comprising a first part (54) and a second part (56) shaped to enclose at least one of the lateral edges (47) of the casing (32) between them, the second part (56) defining at least one recess (68) provided to allow the casing (32) to protrude out of the support structure (34) through said recess (68).