Multi-Layer Battery Pack Enclosure With Cooling Circuit and Air Gap
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Solution Overview
Problem
Conventional traction battery packs face inefficiencies in thermal management and insulation, leading to heating and cooling losses, as they rely on array support structures and lack effective internal cooling circuits and air gaps to optimize battery performance.
Innovation Solution
A cell-to-pack battery system with a multi-layered enclosure assembly featuring an internal cooling circuit and an air gap within the enclosure tray, where the cooling circuit is designed to manage heat and the air gap insulates the cell matrix from the exterior environment, reducing thermal transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional array support structures are used to group and support battery cells, then the battery cells can be organized in multiple individual units, but thermal management efficiency deteriorates due to lack of effective internal cooling circuits and air gaps
Solution Approach 1:
The enclosure tray floor is segmented into multiple functional chambers: a first chamber housing the internal cooling circuit and a second chamber providing an air gap. This segmentation allows simultaneous implementation of active cooling and passive insulation without requiring separate support structures, resolving the contradiction between thermal management efficiency and structural complexity
Solution Approach 2:
The patent merges the support structure function with the thermal management system by integrating the cooling circuit and air gap chambers directly into the enclosure tray floor. This combination eliminates the need for separate array support structures while providing effective thermal management, thus reducing overall device complexity while improving thermal management efficiency
2Reliability
If array support structures are used to support battery cells, then the cells can be grouped in individual units, but thermal insulation deteriorates due to lack of air gaps for reducing thermal transfer
Solution Approach 1:
The floor is segmented to create a second chamber that houses an air gap between the battery cells and the exterior environment. This segmentation provides effective thermal insulation by reducing conductive and convective heat transfer, while the integrated design within the existing enclosure structure avoids increasing overall device complexity
Solution Approach 2:
The air gap acts as an intermediary thermal barrier between the battery cells and the exterior environment. By introducing this intermediate space filled with low-conductivity air, the patent achieves improved thermal insulation without requiring additional insulating materials or complex structural modifications
3Reliability
If conventional enclosure structures without internal cooling circuits are used, then the enclosure can be simpler in design, but thermal management efficiency deteriorates leading to heating and cooling losses
Solution Approach 1:
The internal cooling circuit is integrated into the floor structure itself, allowing cooling to occur at the source where heat is generated by the battery cells. This preliminary cooling action prevents heat accumulation and reduces the overall energy consumption required for thermal management, as cooling occurs before significant heating losses can occur
Solution Approach 2:
The enclosure structure serves its own thermal management needs through the integrated cooling circuit and air gap system. The structure provides both support and thermal regulation functions, eliminating the need for separate, energy-intensive cooling systems while maintaining effective thermal management
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 configuration enhances thermal management and insulation, minimizing heating and cooling losses, thereby improving the efficiency and lifespan of the battery cells by actively removing heat and reducing external thermal influences.
Implementation Method 1
An internal cooling circuit may be provided inside the first chamber for removing heat from the battery cells
Implementation Method 2
The internal cooling circuit includes a plurality of fluid channels that are at least partially separated from one another by a plurality of walls
Implementation Method 3
A second chamber may be provided inside the floor, between the internal wall and the exterior wall, that provides an air gap for insulating the battery cells from an exterior environment
Data Source
AI summary
Traction battery packs are disclosed that include cell-to-pack battery systems. A cell matrix of the cell-to-pack battery system may be positioned within an enclosure assembly of the traction battery pack. The enclosure assembly may include one or more multi-layered structures. Each multi-layered structure may include a first chamber and a second chamber. The first chamber provides an internal cooling circuit for thermally managing the cell matrix, and the second chamber provides an air gap for insulating the cell matrix from an exterior environment.