Battery Rod Cell Cooling via Integrated Contact Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery designs face challenges in achieving effective heat exchange and mechanical resistance while being cost-effective, often requiring complex structural efforts to prevent overheating.
Innovation Solution
The battery employs a heat exchanger with a multi-layer foil material, connected to the rod cells' metal end areas via a common contact plate, using point-by-point laser welding for electrical and mechanical connections, and incorporates a flow control grid and pressure pocket for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If rod cells are cooled via their lateral surface using heat exchanger elements, then heat exchange effectiveness is improved, but structural complexity and manufacturing effort increase significantly
Solution Approach 1:
The patent combines the electrical connection function and thermal management function into a single integrated contact plate structure. The contact plate simultaneously serves as an electrical conductor connecting rod cell terminals and as a heat exchanger cooling the rod cells from the end faces, eliminating the need for separate lateral surface heat exchangers and reducing structural complexity
Solution Approach 2:
Instead of cooling the rod cells from the lateral surface as in conventional designs, the patent inverts the cooling approach by cooling the rod cells from their end faces through the contact plates. This inversion simplifies the overall structure while maintaining effective thermal management
2Temperature
If complex heat exchanger structures are used to cool rod cells, then cooling effectiveness is improved, but manufacturing cost and production simplicity worsen
Solution Approach 1:
The contact plate integrates multiple functions (electrical connection and thermal management) into a single component, simplifying the manufacturing process. The laser welding technique further simplifies production by enabling rapid, automated assembly of the contact plates to the rod cells without complex machining or assembly steps
Solution Approach 2:
The patent replaces complex mechanical heat exchanger structures with a simplified system using contact plates and laser welding. This substitution of manufacturing methods dramatically reduces production complexity and cost while maintaining cooling effectiveness
3Temperature
If rod cells are cooled via their lateral surface, then heat exchange is achieved, but mechanical resistance and structural strength are reduced
Solution Approach 1:
The patent inverts the cooling location from lateral surfaces to end faces of the rod cells. This inversion allows the cooling function to be integrated into the contact plates without compromising the mechanical strength of the rod cell assembly, as the end-face cooling approach maintains better structural integrity
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 cooling efficiency, mechanical strength, and cost-effectiveness by directly cooling the rod cells through their metal poles, ensuring effective heat transfer and compact, space-saving battery architecture.
Implementation Method 1
the contact plates are thermally conductively connected to a flat surface through which liquid flows that extends parallel to it heat exchanger stand
Implementation Method 2
a flow control grid is enclosed between the two foil walls of the heat exchanger in order to distribute the heat transfer medium optimally for the heat exchange over the inner surfaces of the heat exchanger as it flows through
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The battery (1) has rod cells (7) arranged side by side in several rows, the end electrical contacts of which are each electrically connected to each other in parallel and series by a common contact plate (16). For effective cooling, a flat heat exchange pocket (19) through which a heat transfer fluid flows is located against these contact plates (16). This pocket consists of a multilayer thin film having an electrically insulating outer layer.