EV Battery Pack Spacer With Flow-Turning Ribs
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Solution Overview
Problem
Existing electric vehicle battery packs face challenges in packaging due to the straightforward flow of coolant, which limits flexibility in positioning the inlet and outlet plenums and does not efficiently manage thermal energy distribution.
Innovation Solution
A battery pack spacer with laterally extending ribs that turns the coolant flow from the inlet to the outlet side, creating channels with the battery cells and base to facilitate efficient cooling, potentially using blocks that turbulate and direct the flow through slits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If coolant flows in a single direction between battery cells, then the cooling path is simple, but the lateral width of the battery pack increases and packaging flexibility is reduced
Solution Approach 1:
The coolant flow is redirected from a lateral path to a vertical path using ribs that extend in the lateral direction but cause flow turnover to the outlet side. This dimensional change in flow direction allows the inlet and outlet plenums to be positioned on the same lateral side, reducing the lateral width requirement while maintaining effective cooling.
Solution Approach 2:
The battery pack is divided into functional zones using spacers with ribs that segment the coolant flow path. The ribs create distinct inlet regions, cooling channels, and outlet regions, allowing independent optimization of each zone and enabling compact packaging while maintaining efficient thermal management.
2Adaptability or versatility
If coolant flow is turned using ribs, then packaging flexibility is improved, but the spacer structure complexity increases
Solution Approach 1:
The spacer serves multiple functions simultaneously: it provides structural support between battery cell layers, defines coolant flow channels, directs coolant turnover from inlet to outlet side, and positions inlet/outlet plenums. This multi-functionality reduces the need for separate components, achieving packaging flexibility without proportionally increasing overall system complexity.
Solution Approach 2:
The flow-turning ribs are integrated directly into the spacer structure rather than being separate components. This merging of flow control functions into the structural spacer element achieves the desired packaging flexibility while minimizing additional complexity, as the same component performs both structural and flow management roles.
3Temperature
If blocks are added to turbulate flow, then thermal management efficiency is improved, but the spacer complexity and manufacturing difficulty increase
Solution Approach 1:
Blocks with internal slit structures are integrated into the spacer to create turbulence in the coolant flow. These porous-like structures with controlled openings enhance mixing and thermal transfer efficiency while being manufacturable as integrated features of the spacer, balancing thermal performance with manufacturing feasibility.
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 packaging flexibility by reducing the lateral width of the battery pack and improves thermal management by effectively guiding and distributing thermal energy away from the battery cells.
Implementation Method 1
the at least one rib receives the flow from an inlet side of the battery pack and turns the flow to exit the battery pack at an outlet side
Implementation Method 2
The blocks turbulate the flow of the coolant
Implementation Method 3
the base and the battery cell provide opposing sides of a channel for communicating the flow through the battery pack
Data Source
AI summary
An example battery pack spacer includes a base and at least one rib extending laterally from the base. The rib is configured to turn flow of a coolant through a battery pack.