Battery Module Heat Exchanger With Conformal Outer Wall

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Solution Overview

Problem

Existing heat exchangers fail to match the fine shape of power storage modules, leading to gaps and reduced efficiency in heat exchange due to vertical deformation of outer plates at nodes, which decreases the sectional area of refrigerant flow paths and increases temperature.

Innovation Solution

A heat exchanger with a base member and outer wall where the outer wall has a higher coefficient of linear expansion, lower yield stress, and lower modulus of elasticity than the base member, allowing it to deform easily and match the shape of the power storage module, with refrigerant flowing through main and sub-flow paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If the outer plate deforms vertically at the nodes to match the power storage module surface, then the contact area increases, but gaps still occur between the outer plate and power storage module reducing heat exchange efficiency

Engineering Contradiction:

Improvecontact areaVSAvoidheat exchange efficiency

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The outer wall is designed as a thin-walled structure with lower yield stress and lower modulus of elasticity compared to the base member, enabling it to deform flexibly and conform to the fine surface shape of the power storage module, eliminating gaps and improving heat exchange efficiency

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The outer wall material parameters are specifically changed to have lower yield stress and lower modulus of elasticity than the base member, allowing the outer wall to deform more easily and match the complex surface geometry of the power storage module, thereby eliminating gaps while maintaining contact area

Inventive Principle:

Principle #35Parameter changes

2Area of stationary object

If the outer wall deforms easily to match the power storage module shape, then contact area increases, but the structural integrity of the heat exchanger may be compromised

Engineering Contradiction:

Improvecontact areaVSAvoidstructural integrity

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The heat exchanger is segmented into two functional parts: the base member with high strength and stiffness for structural integrity, and the outer wall with low yield stress and low modulus of elasticity for conformal deformation, allowing each part to fulfill its specific function without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat exchanger uses a composite structure combining materials with different mechanical properties - the base member uses high-strength material while the outer wall uses material with lower yield stress and lower modulus of elasticity, creating a composite system that achieves both structural integrity and shape conformity

Inventive Principle:

Principle #40Composite materials

3Device complexity

If the outer plate maintains a planar shape without fine deformation, then structural simplicity is maintained, but gaps occur reducing the sectional area of refrigerant flow path

Engineering Contradiction:

Improvestructural simplicityVSAvoidrefrigerant flow path area

Core Design Contradiction:

Device complexityVSQuantity of substance

Solution Approach 1:

The thin-walled outer wall structure enables the heat exchanger to achieve complex deformed shapes without significantly increasing device complexity, as the flexibility is inherent in the thin-walled design rather than requiring additional mechanical components

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Changing the material parameters of the outer wall (lower yield stress, lower modulus of elasticity) allows it to deform conformally to the power storage module surface, eliminating gaps and maximizing the refrigerant flow path area without requiring complex structural modifications

Inventive Principle:

Principle #35Parameter changes

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

Enhances heat exchange efficiency by increasing contact area, reducing pressure loss, and improving thermal response, while maintaining structural integrity and reducing the size and thickness of the heat exchanger.

Implementation Method 1

The outer wall has a coefficient of linear expansion larger than that of the base member

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

The heat exchanger exchanges heat with the heat exchange object using refrigerant flowing through a main flow path and a sub-flow path

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

refrigerant flowing through a main flow path and a sub-flow path

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250309404A1Power storage device and method of manufacturing power storage device

Publication Date: 2025.10.02 TOYOTA JIDOSHA KK

AI summary

A power storage device includes a power storage module and a heat exchanger whose heat exchange object is the power storage module. The power storage module is joined to the heat exchanger with an adhesive. The heat exchanger exchanges heat with the heat exchange object using refrigerant flowing through a main flow path and a sub-flow path. The heat exchanger includes a base member and an outer wall. The outer wall is provided in the base member. The main flow path is formed inside the base member. The sub-flow path is formed of the base member and the outer wall. The outer wall deforms more easily than the base member and the power storage module.