Battery Pack Thermal Exchange Plates With Thermal Break Isolation

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Solution Overview

Problem

Conventional thermal management systems for traction battery packs in electrified vehicles fail to effectively inhibit thermal energy transfer between different areas of the battery pack, which can lead to cascading thermal events and reduced efficiency.

Innovation Solution

A thermal management system incorporating a thermal exchange device with a first metal or metal alloy plate and a second polymer-based plate, featuring apertures that act as thermal breaks to inhibit thermal energy transfer, along with coolant passageways and thermal interface materials to manage heat distribution across the battery cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermal management systems are used without thermal breaks, then thermal energy can transfer freely between different areas of the battery pack, but this leads to cascading thermal events and reduced safety

Engineering Contradiction:

ImprovesafetyVSAvoidthermal energy transfer

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The thermal exchange device is segmented into multiple zones using thermal breaks (apertures or low-conductivity material regions) that divide the continuous thermal path into separate segments. This segmentation prevents thermal energy from propagating freely across the entire battery pack, isolating thermal events to specific zones while maintaining coolant flow through the divided structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A thermal break acts as an intermediary element within the thermal exchange device that selectively interrupts thermal energy transfer between adjacent battery cell groups. The thermal break is integrated into the thermal exchange device structure, allowing it to mediate between the need for thermal management and the need to prevent thermal propagation, while coolant continues to flow through the device.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal breaks are added to the thermal exchange device, then thermal energy transfer between different areas is inhibited, but the device complexity increases

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidthermal exchange device structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermal exchange device is designed to perform multiple functions simultaneously: it provides coolant flow paths for thermal management, incorporates thermal breaks for thermal isolation, and maintains structural support for battery cells. By integrating these diverse functions into a single device, the overall system complexity is reduced despite the added thermal management capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If a single-material thermal exchange device is used, then manufacturing is simpler, but thermal energy transfer cannot be effectively controlled between different areas

Engineering Contradiction:

Improvethermal exchange device fabricationVSAvoidthermal isolation capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The thermal exchange device employs composite material construction, combining materials with different thermal conductivities in specific regions. High-conductivity materials are used in coolant flow paths for efficient heat transfer, while low-conductivity materials or apertures are strategically placed to create thermal breaks. This composite approach enables precise control over thermal energy transfer while maintaining manufacturability through established composite fabrication techniques.

Inventive Principle:

Principle #40Composite materials

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

The system effectively blocks thermal energy transfer between different areas of the battery pack, preventing cascading thermal events and enhancing thermal management efficiency within the traction battery pack.

Implementation Method 1

at least one thermal break in the thermal exchange device, the at least one thermal break configured to inhibit thermal energy transfer from a first area of the thermal exchange device to a different, second area of the thermal exchange device

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

at least one coolant passageway that communicates a coolant between the first plate and the second plate

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20240079669A1Traction battery pack thermal management system and thermal management method

Publication Date: 2024.03.07 FORD GLOBAL TECH LLC

AI summary

A thermal management system for a traction battery pack includes at least one cell stack having a plurality of battery cells, a thermal exchange device having a first plate, a second plate, and at least one coolant passageway that communicates a coolant between the first plate and the second plate. The first plate is a first material. The second plate is a second material that is different than the first material. The thermal management system further includes at least one thermal break in the thermal exchange device. The at least one thermal break configured to inhibit thermal energy transfer from a first area of the thermal exchange device to a different, second area of the thermal exchange device.