Split Thermal Fin Battery Frames for Low-TIM Pack Cooling
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Solution Overview
Problem
Existing battery packs in electrified vehicles require significant amounts of thermal interface material (TIM) to enhance thermal conductivity between thermal fins and heat exchanger plates, which is costly and complex.
Innovation Solution
Implementing a split thermal fin design within the battery array frame, where the thermal fin is split into two sections, allowing for reduced or eliminated use of TIM by ensuring natural contact or positive contact with the heat exchanger plate through features like ridges, protruding fins, or spring inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal interface material is used to enhance thermal conductivity between thermal fins and heat exchanger plates, then thermal conductivity is improved, but cost and complexity increase
Solution Approach 1:
The patent extracts and eliminates the thermal interface material from the system by designing a split thermal fin configuration where the first and second thermal fin sections directly contact the heat exchanger plate and each other, respectively. This direct contact design removes the need for TIM while maintaining thermal conductivity through precise mechanical interfacing features.
Solution Approach 2:
The thermal fin is segmented into two separate sections (first thermal fin section and second thermal fin section) that can be independently positioned and contacted with the heat exchanger plate. This segmentation allows for direct thermal contact without requiring thermal interface material, as each section can be precisely fitted to its contact surface.
2Temperature
If thermal interface material is used to enhance thermal conductivity, then thermal conductivity is improved, but cost increases
Solution Approach 1:
The patent removes the thermal interface material substance from the system entirely by using direct contact between the split thermal fin sections and the heat exchanger plate. The mechanical interface features (ridges, slots, protrusions) enable direct thermal contact without requiring any additional material substances, thereby eliminating the cost associated with TIM.
3Ease of manufacture
If a single thermal fin design is used, then assembly is simpler, but thermal contact without TIM is difficult to achieve
Solution Approach 1:
The thermal fin is divided into two sections that can be independently assembled into the frame body. The first thermal fin section contacts the heat exchanger plate while the second thermal fin section contacts the first section. This segmentation allows each section to be independently positioned and secured, ensuring reliable thermal contact through the split configuration rather than requiring a single complex fin design.
Solution Approach 2:
Different portions of the thermal fin system have different functions: the first thermal fin section is optimized for contacting the heat exchanger plate, while the second thermal fin section is optimized for contacting the first section. This local differentiation of function and geometry enables reliable thermal contact at each interface without requiring the entire fin to be designed for a single purpose.
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
Reduces the need for thermal interface material, simplifies assembly, and lowers costs while maintaining effective thermal conductivity between thermal fins and heat exchanger plates.
Implementation Method 1
a second thermal fin section held within the frame body and received in abutting contact with the first thermal fin section
Data Source
AI summary
Battery pack designs are provided for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.