Compressible Cooler Plate Contact for Battery Module Cooling

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Solution Overview

Problem

Existing power storage devices face challenges in bringing coolers into close thermal contact with the outer surface of the lower case due to differences in material rigidity, making it difficult to conform effectively.

Innovation Solution

The cooler is made of a member with lower rigidity than the lower case and is pressed into contact using force exerting portions such as fastening, reinforcing, projecting, and damper members, which deform elastically to conform to the lower case surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the cooler is made of a member with lower rigidity than the lower case, then the cooler can be brought into close contact with the outer surface of the lower case to conform thereto, but the cooler may not maintain sufficient structural stability

Engineering Contradiction:
Improvecontact precisionVSAvoidstructural stability
Core Design Contradiction:
Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent changes the rigidity parameter of the cooler by selecting materials with lower rigidity (such as aluminum or aluminum alloys) compared to the lower case. This parameter change allows the cooler to deform and conform to the outer surface of the lower case, achieving close thermal contact while maintaining structural stability through the force exerting portions.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent introduces force exerting portions (such as elastic members, resilient members, or biasing members) that dynamically adjust the position and contact pressure of the cooler against the lower case. These dynamic elements allow the cooler to maintain close contact while accommodating variations in the lower case surface, thereby resolving the contradiction between conformability and structural stability.

Inventive Principle:
Principle #15Dynamics

2Manufacturing precision

If the cooler is pressed toward the bottom portion using force exerting portions, then the cooler can conform to the outer surface of the lower case, but the device complexity increases

Engineering Contradiction:
Improvecontact precisionVSAvoidstructural complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs flexible force exerting portions such as elastic members, resilient members, or thin-walled structures that can deform to conform the cooler to the lower case surface. These flexible elements achieve close thermal contact without requiring complex rigid mechanical systems, thereby reducing overall device complexity while maintaining contact precision.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The force exerting portions are designed to automatically adjust and maintain contact between the cooler and the lower case without requiring external control systems. The elastic or resilient nature of these members allows them to self-regulate their force application, eliminating the need for additional sensors, actuators, or control mechanisms, thus avoiding increased device complexity.

Inventive Principle:
Principle #25Self-service

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 configuration ensures close thermal contact between the cooler and the lower case, enhancing cooling efficiency while potentially reducing weight by optimizing the number and placement of fastening pieces.

Implementation Method 1

The cooler is made of a member having a rigidity lower than that of the lower case. The cooler includes a force exerting portion that exerts a force toward the bottom portion. By providing the notch portion in the root portion of the fastening piece portion connected to the holding portion, the fastening piece portion is deformed and acts as a spring structure when the fastening piece portion is fastened to the lower case.

Methodology Applied
Scientific EffectElastic deformation: Elasticity

Implementation Method 2

a cooler that is provided on a side of the outer surface of the bottom portion and cools the one or more power storage modules via the bottom portion

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12500285B2Power storage device comprising compressible cooler plate
Publication Date: 2025.12.16 TOYOTA JIDOSHA KK
  • US12500285B2 patent drawing
  • US12500285B2 patent drawing
  • US12500285B2 patent drawing

AI summary

A power storage device includes a lower case having a bottom portion including an inner surface and an outer surface, one or more power storage modules thermally connected to the inner surface of the bottom portion, and a cooler that is provided on a side of the outer surface of the bottom portion and cools the one or more power storage modules via the bottom portion. The cooler is made of a member having a rigidity lower than that of the lower case. The cooler includes a force exerting portion that exerts a force toward the bottom portion.