Battery Pack Attachment Features for Thermal Coupling

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Solution Overview

Problem

The existing battery packs for electrified vehicles face inefficiencies in heat dissipation due to gaps between battery cells and heat exchanger plates, which can reduce the thermal effectiveness and impact the capacity and life of battery cells.

Innovation Solution

The battery pack design incorporates attachment features such as clip arms and apertures or slots on the heat exchanger plate and battery assembly, allowing for secure mechanical and thermal coupling, enabling effective heat management by ensuring direct contact and flexible engagement between the battery assembly and the heat exchanger plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional battery packs are used without integrated attachment features, then the structure is simpler and easier to manufacture, but thermal coupling effectiveness deteriorates due to gaps between battery cells and heat exchanger plate

Engineering Contradiction:

Improvethermal coupling effectivenessVSAvoidstructure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines mechanical attachment and thermal coupling functions into a single integrated feature. The attachment feature includes both a mechanical engagement portion (clip arm with aperture) and a thermal conduction portion (heat transfer surface), eliminating the need for separate mechanical fasteners and thermal interface materials. This merging resolves the contradiction by achieving effective thermal coupling without adding structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The attachment feature serves multiple functions simultaneously: it provides mechanical securing (retaining battery assembly to heat exchanger plate), thermal conduction (transferring heat from battery cells to heat exchanger), and gap elimination (ensuring direct contact between components). This multi-functionality resolves the contradiction by improving thermal coupling effectiveness while maintaining simple structure through a single universal component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If gaps exist between battery cells and heat exchanger plate, then manufacturing and assembly are easier, but heat dissipation efficiency deteriorates

Engineering Contradiction:

Improveassembly easeVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The attachment feature is pre-configured with the battery assembly during manufacturing, with the clip arm and aperture positioned to ensure direct contact with the heat exchanger plate. This preliminary positioning eliminates gaps before the battery enters service, resolving the contradiction by ensuring heat dissipation efficiency without compromising assembly ease, as the feature is already in its optimal position.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The thermal conduction portion of the attachment feature acts as an intermediary between the battery cells and the heat exchanger plate. It provides a direct thermal pathway that eliminates air gaps (which are poor thermal conductors), ensuring efficient heat transfer from the battery assembly to the cooling plate while maintaining simple assembly procedures.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If flexible attachment features are used to ensure direct contact, then thermal coupling improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvethermal couplingVSAvoidengagement precision

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The clip arm is designed with flexible material properties and appropriate geometric dimensions (thickness, length, cross-section) that allow it to deflect and conform to slight variations in manufacturing tolerances. This parameter optimization enables the flexible attachment feature to maintain direct thermal contact without requiring extremely tight manufacturing precision, resolving the contradiction between improved thermal coupling and reduced precision requirements.

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

This design enhances thermal coupling, improving heat dissipation and extending the life and capacity of battery cells by ensuring efficient heat transfer between the battery cells and the heat exchanger plate.

Implementation Method 1

attachment features for both mechanically securing the battery assembly to the enclosure and thermally coupling the battery assembly to the heat exchanger plate

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

thermally couple the battery assembly to the heat exchanger plate... improving heat dissipation and extending the life and capacity of battery cells by ensuring efficient heat transfer

Methodology Applied

Scientific EffectThermal Conduction: Conduction (thermal)

Data Source

PatentUS10446893B2Electrified vehicle battery packs with battery attachment features

Publication Date: 2019.10.15 FORD GLOBAL TECH LLC

AI summary

A battery pack includes a heat exchanger plate having a first attachment feature and a battery assembly having a second attachment feature configured to engage the first attachment feature as the battery assembly is moved against the heat exchanger plate to thermally couple the battery assembly to the heat exchanger plate.