Plastic-Metal Composite Cooling Plate for Li-Ion Batteries
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Solution Overview
Problem
Conventional metallic cooling plates for lithium ion batteries are prone to short circuits and are costly, while injection-molded plastic solutions face challenges in fluidity and thermal integrity, necessitating a more effective and cost-efficient temperature control solution.
Innovation Solution
A plastic-metal composite temperature control plate formed with a metal fiber fabric surrounded by a thermoset plastic, utilizing a compression molding process to create a thermally and dimensionally stable plate with enhanced thermal conductivity, which is electrically insulating and resistant to cooling media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metallic cooling plate is used for temperature control, then thermal conductivity is improved, but electrical insulation deteriorates causing short circuit risks
Solution Approach 1:
The patent applies composite materials by combining metal fibers (for thermal conductivity) with thermoset plastic (for electrical insulation). The metal fiber fabric is embedded within the plastic matrix, creating a composite temperature control plate that simultaneously achieves both thermal performance and electrical insulation, resolving the contradiction between heat dissipation and short circuit prevention.
2Ease of manufacture
If injection-molding plastic is used to produce temperature control plates, then manufacturing cost is reduced, but thermal and dimensional integrity deteriorates
Solution Approach 1:
The patent applies parameter changes by transitioning from thermoplastic injection-molding to thermoset compression-molding. The thermoset plastic undergoes chemical crosslinking during curing, transforming from a deformable state to a rigid, dimensionally stable state. This parameter change in the material's physical-chemical properties enables both cost-effective manufacturing and superior thermal/dimensional integrity.
Solution Approach 2:
The patent incorporates metal fiber fabric as a reinforcing component within the thermoset plastic matrix. This composite structure enhances the thermal conductivity and dimensional stability of the temperature control plate while maintaining manufacturability through compression molding, addressing both cost and performance requirements.
3Temperature
If conventional metallic plates are used, then thermal performance is improved, but production cost deteriorates
Solution Approach 1:
The patent uses a composite material system where metal fibers provide the thermal conduction pathways necessary for effective heat dissipation, while the thermoset plastic matrix reduces material cost compared to solid metal plates. The composite structure achieves comparable thermal performance to metallic plates at lower production cost.
Solution Approach 2:
The patent applies local quality by concentrating metal fibers within the plastic matrix rather than using solid metal throughout. The metal fibers are strategically distributed to create thermal conduction pathways where needed, providing localized thermal enhancement while maintaining overall cost-effectiveness through the use of less expensive plastic material.
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 solution provides a cost-effective, thermally efficient, and dimensionally stable temperature control plate that effectively dissipates heat from lithium ion batteries and other temperature-exposed components, offering improved safety and reduced production costs compared to conventional metallic plates.
Implementation Method 1
by virtue of the fact that the conductive metal fiber fabric is surrounded by an electrically insulating thermoset plastic, the resin layer on the surface is able, advantageously, to ensure electrical insulation
Implementation Method 2
a plastic-metal composite material comprising a metal fiber fabric that is surrounded by a thermoset plastic can be produced, advantageously, more easily and more inexpensively... able outstandingly to dissipate the heat from battery cells
Implementation Method 3
thermoset plastics are resistant to cooling media that are customarily used. This has the advantage, furthermore, that the metal fabric is not attacked
Implementation Method 4
A plastic-metal composite material which comprises a metal fiber fabric that is surrounded by a thermoset plastic may be produced, in particular, by a compression molding process
Data Source
AI summary
A temperature control plate for controlling the temperature of components. The temperature control plate is formed of a plastic-metal composite material which includes a metal fiber fabric that is surrounded by a thermoset plastic. A casing contains the components. The temperature control plate is configured for conducting heat away from temperature-exposed components.