Traction Battery Tray With Direct Coolant Channels
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Solution Overview
Problem
Existing traction battery thermal management systems for motor vehicles face inefficiencies in heat transfer due to thermal resistance from cold plates and thermal interface materials, limiting effective temperature regulation of battery cells.
Innovation Solution
A traction battery design featuring a tray or manifold with an open channel or cavity that allows direct contact between liquid coolant and the cells, eliminating thermal resistance from cold plates and thermal interface materials, thereby enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cold plates and thermal interface materials are used for thermal management, then thermal resistance increases, but heat transfer efficiency decreases
Solution Approach 1:
The patent removes cold plates and thermal interface materials from the thermal management system, allowing coolant to flow directly through channels formed by the battery cell holders themselves. This extraction of the intermediate thermal management components eliminates the thermal resistance they introduced while maintaining effective heat transfer through direct coolant contact with cells.
Solution Approach 2:
The patent integrates the thermal management function directly into the battery cell holder structure. The holders are designed with internal channels that serve dual purposes: mechanical support for the cells and thermal management pathways for coolant flow. This merging eliminates the need for separate cold plate components and reduces overall thermal resistance.
2Loss of energy
If direct coolant contact with cells is implemented, then heat transfer efficiency improves, but system complexity increases
Solution Approach 1:
The battery cell holders are designed to perform multiple functions simultaneously: providing mechanical support for the cells, enabling electrical connections, and serving as the thermal management system through integrated coolant channels. This multi-functionality reduces overall system complexity by eliminating separate components for each function.
Solution Approach 2:
The patent changes the structural parameters of the cell holders by incorporating internal coolant flow channels within the holder walls. This parameter change allows direct coolant contact with cells while utilizing the existing holder structure, avoiding the need for additional complex cooling components.
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 improves thermal regulation by reducing thermal resistance, enabling more efficient heat transfer between the coolant and cells, maintaining optimal cell temperatures and enhancing overall battery performance.
Implementation Method 1
a liquid coolant and the cells, eliminating thermal resistance from cold plates and thermal interface materials, thereby enhancing heat transfer efficiency
Data Source
AI summary
A traction battery for a vehicle includes a tray having an outer surface defining an open channel configured to circulate liquid coolant. A plurality of cells are stacked in an array and each has a dielectric material surrounding at least a portion of the cell. The array is disposed on the outer surface and covers the channel such that a side of the array is in direct contact with the coolant during operation.