Battery Module Heat Transfer Surface Cavities
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Solution Overview
Problem
Existing battery modules for electric vehicle traction batteries face challenges in reducing setting force during assembly, which can lead to deformation and require high holding forces due to the use of paste-like heat-conducting materials that flow over long distances, necessitating additional mounting aids.
Innovation Solution
The introduction of cavities between partial surfaces on the heat transfer surface allows excess heat-conducting material to flow laterally into these cavities, reducing flow paths and thus the static pressure required, enabling a lower setting force and preventing deformation, while maintaining full-surface contact with the temperature control device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If paste-like heat-conducting material is used to thermally couple battery modules to the temperature control device, then thermal coupling effectiveness is improved, but setting force and holding force requirements increase
Solution Approach 1:
The heat transfer surface is segmented into multiple partial surfaces with cavities between them. This segmentation allows the paste-like heat-conducting material to be contained in smaller sections, reducing the flow distance required and thereby reducing the setting force needed during assembly while maintaining effective thermal coupling.
Solution Approach 2:
The cavities create localized regions where the heat-conducting material can be concentrated. This local quality enhancement ensures adequate thermal coupling in specific areas without requiring high setting forces across the entire surface, as the material is contained and distributed more efficiently.
2Temperature
If high setting force is applied to ensure full contact between heat transfer surfaces, then thermal coupling is improved, but component deformation occurs
Solution Approach 1:
By dividing the heat transfer surface into partial surfaces separated by cavities, the patent reduces the total contact area requirement. This segmentation allows adequate thermal coupling with lower setting forces, preventing the high forces that would otherwise cause component deformation.
Solution Approach 2:
The cavities function similarly to porous structures by providing spaces that accommodate and contain the paste-like heat-conducting material. This approach enables effective thermal coupling without requiring excessive compression forces that would deform the components.
3Area of stationary object
If continuous contact surface is maintained between heat transfer surfaces, then thermal coupling area is maximized, but flow resistance of heat-conducting material increases
Solution Approach 1:
The continuous contact surface is replaced with multiple partial surfaces separated by cavities. This segmentation reduces the flow resistance of the paste-like heat-conducting material by breaking up long flow paths into shorter segments, while the cumulative contact area of the partial surfaces maintains adequate thermal coupling.
Solution Approach 2:
The patent introduces a vertical dimension with cavities between partial surfaces, allowing the heat-conducting material to flow laterally into these cavities. This dimensional change reduces the horizontal flow distance required, decreasing flow resistance while maintaining effective thermal coupling through the combined contact area of multiple partial surfaces.
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
This approach reduces the setting force needed during assembly, prevents deformation of components, and allows for faster cycle times by minimizing the pressure exerted on the temperature control device, ensuring effective thermal coupling without compromising contact area.
Implementation Method 1
Heat transfer surfaces of traction battery modules can be thermally coupled to the temperature control unit using gap filler, a paste-like heat transfer material
Implementation Method 2
When pressure is applied, the heat-conducting material yields and flows in the direction of a lower pressure
Data Source
AI summary
A battery module for a traction battery of an electric vehicle is disclosed. The battery module includes a heat transfer surface for tempering cells of the battery module and at least one cavity disposed between partial surfaces of the heat transfer surface for receiving excess heat conductive material.