Battery Thermal Management Assembly with Integrated Fluid Channels

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Solution Overview

Problem

Conventional thermal management systems for traction batteries in electrified vehicles face complexity and inefficiency in managing thermal energy, particularly in integrating fluid channels with different material compositions to effectively cool or heat battery packs.

Innovation Solution

A thermal management assembly utilizing a first structure with a polymer material and a second structure with a metal or metal alloy, secured together by an overmolded third structure, to create fluid channels that facilitate thermal energy exchange between the battery array and a fluid, simplifying assembly and reducing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional thermal management systems use separate components for fluid channels and structural support, then structural integrity is maintained, but device complexity increases

Engineering Contradiction:

Improvethermal management system complexityVSAvoidstructural integrity

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent combines the fluid channel structure and structural support into a single integrated component. The first structure provides both the fluid channel boundaries and structural support functions, eliminating the need for separate components and reducing overall system complexity while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The first structure serves multiple functions simultaneously: it provides structural support for the battery pack and defines the fluid channel boundaries for thermal management. This multi-functional design reduces the number of components needed and simplifies the overall system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If thermal management assembly uses multiple separate structures for fluid channels, then manufacturing flexibility is improved, but assembly complexity increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent integrates the fluid channel structure with the battery pack enclosure into a unified component. This integration reduces the number of assembly steps and simplifies the assembly process while maintaining the flexibility to manufacture different configurations through molding variations.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If battery pack uses traditional cooling systems with separate components, then thermal management effectiveness is maintained, but weight increases

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidbattery pack weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent merges the thermal management functions into the existing battery pack structure, eliminating the need for separate cooling components. This integration reduces overall weight while maintaining effective thermal management through the fluid channels formed by the integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

4Temperature

If battery pack uses traditional cooling systems with separate components, then thermal management effectiveness is maintained, but height increases

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidbattery pack height

Core Design Contradiction:

TemperatureVSLength of moving object

Solution Approach 1:

The patent integrates the fluid channel structure within the battery pack enclosure, allowing thermal management components to be embedded rather than added as separate external components. This integration reduces the overall height of the battery pack while maintaining effective thermal management.

Inventive Principle:

Principle #5Merging (Combining)

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 solution enhances thermal management efficiency by allowing for effective cooling or heating of battery packs, reducing the overall height and weight of the battery pack while maintaining thermal performance, and simplifying the assembly process.

Implementation Method 1

The second structure is configured to exchange thermal energy between a battery array and a fluid communicated through a fluid channel

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a fluid communicated through a fluid channel that is bounded by the first and second structures

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS10411314B2Battery thermal management assembly and method

Publication Date: 2019.09.10 FORD GLOBAL TECH LLC

AI summary

An exemplary battery thermal management assembly includes a first structure having a first material composition, and a second structure having a different, second material composition. The second structure is configured to exchange thermal energy between a battery array and a fluid communicated through a fluid channel that is bounded by the first and second structures. An exemplary battery thermal management method includes securing a first structure of a first material composition relative to a second structure of a different, second material composition to provide a fluid channel. The method further includes using the second structure to pass thermal energy between a battery and a fluid within the fluid channel.