Battery Thermal Interface Material Installation Assembly
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Solution Overview
Problem
Existing methods for installing thermal interface materials within battery arrays face challenges in ensuring complete and efficient filling of cavities between battery cell assemblies and thermal exchange plates, leading to potential gaps and reduced thermal conductivity.
Innovation Solution
A method involving the use of a conduit system within the thermal exchange plate to deliver and hold thermal interface material, where the material is injected as a liquid and can cure in place, with strategically designed conduit outlets and structural features to guide and fill cavities effectively, reducing leakage and ensuring good thermal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal interface material is installed using conventional methods, then installation can be performed, but gaps may remain in the cavity leading to reduced thermal conductivity
Solution Approach 1:
The patent utilizes a pump to deliver liquid thermal interface material through a conduit system into the cavity. The liquid form allows the material to flow completely into the cavity space, ensuring gapless filling. After curing, the material provides reliable thermal conductivity between the thermal exchange plate and battery cell assemblies.
Solution Approach 2:
The patent changes the physical state of the thermal interface material from solid to liquid during installation, allowing it to flow and fill the cavity completely. After installation, the material cures to its final state, providing both complete filling and reliable thermal conductivity.
2Reliability
If more thermal interface material is used to ensure complete filling, then thermal contact is improved, but material cost and waste increase
Solution Approach 1:
The pump-based liquid delivery system provides precise control over material placement, delivering the thermal interface material directly to where it is needed in the cavity. This targeted delivery ensures complete filling without excessive material usage or waste.
3Ease of manufacture
If conventional installation methods are used, then installation can be performed, but material leakage occurs increasing complexity
Solution Approach 1:
The pump-based liquid delivery system provides controlled material placement through the conduit system, preventing uncontrolled leakage. The liquid form allows precise delivery, and the curing process seals the material in place, simplifying the overall installation process while eliminating leakage issues.
Solution Approach 2:
By changing the material from solid to liquid during installation and then curing it in place, the system achieves controlled placement without leakage. The liquid state enables flow control through the conduit, and curing locks the material in the desired position.
4Manufacturing precision
If multiple conduit outlets are used to fill different areas, then complete cavity filling is achieved, but conduit complexity increases
Solution Approach 1:
The conduit system is segmented into multiple outlets positioned at different locations within the thermal exchange plate. Each outlet delivers material to specific areas of the cavity, ensuring complete filling of the entire cavity space through coordinated delivery from multiple points.
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 approach ensures complete filling of cavities without gaps, enhancing thermal conductivity and reducing material usage and costs by minimizing leakage and excess material, thereby improving the thermal management of battery packs.
Implementation Method 1
The thermal interface material can be incorporated into other areas of the battery pack... to ensure good thermal contact between the thermal exchange plate and other areas of the battery pack
Implementation Method 2
The coolant carries the thermal energy away from the battery pack to reduce thermal energy levels in the battery cell assemblies
Data Source
AI summary
An exemplary thermal interface material installation method includes, among other things, moving a material through a conduit to a cavity within a battery array. The conduit is at least partially provided by a thermal exchange plate of the battery array. The method further includes holding the material within the cavity to provide a thermal interface material between the thermal exchange plate and at least one battery cell assembly. An exemplary battery thermal interface material installation assembly includes a thermal exchange plate including a conduit with at least one inlet that opens to an exterior of a battery array, and at least one outlet that opens to a cavity between the thermal exchange plate and a plurality of battery cell assemblies.