Conforming Bracket Flexes to Align Battery Pack with Thermal Plate
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Solution Overview
Problem
Existing battery pack retention systems face inefficiencies due to dimensional variations between the thermal exchange plate and battery array, leading to gaps that reduce thermal transfer efficiency and require additional thermal interface materials.
Innovation Solution
A conforming bracket that flexes to align with the thermal exchange plate, featuring platforms, rail members, and pockets that secure the battery array, reducing deformation and gaps by conforming to irregularities in the thermal exchange plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid retention structures are used to secure the battery array, then structural strength is improved, but gaps form due to dimensional variations reducing thermal transfer efficiency
Solution Approach 1:
The retention structure incorporates flexible elements that allow dynamic adjustment to accommodate dimensional variations between the thermal exchange plate and battery array. The flexible retention members can bend and conform to the actual geometry, eliminating gaps while maintaining secure attachment, thus preserving both structural strength and thermal transfer efficiency.
Solution Approach 2:
The patent changes the physical state of the retention structure from rigid to flexible, allowing it to adapt its shape. This parameter change enables the retention system to conform to dimensional variations without creating gaps, thereby maintaining thermal exchange efficiency while still providing necessary structural support.
2Manufacturing precision
If additional thermal interface materials are used to fill gaps, then thermal transfer efficiency is improved, but device complexity and material usage increase
Solution Approach 1:
The patent extracts and eliminates the need for additional thermal interface materials by designing a retention structure that prevents gap formation in the first place. The flexible retention members directly bridge the dimensional variations, making thermal interface materials unnecessary and thereby reducing device complexity and material usage.
Solution Approach 2:
The retention structure is designed to preliminarily accommodate dimensional variations through its flexible nature, preventing gap formation before thermal interface materials would be needed. This preliminary adaptation to geometry variations eliminates the requirement for additional materials and simplifies the overall assembly process.
3Manufacturing precision
If the conforming bracket is made more flexible to reduce gaps, then thermal transfer efficiency is improved, but structural strength decreases
Solution Approach 1:
The retention structure is segmented into multiple flexible members rather than a single rigid component. This segmentation allows each member to independently flex and conform to local dimensional variations, maintaining thermal contact while distributing mechanical loads across multiple elements, thus preserving overall structural strength.
Solution Approach 2:
The patent applies local quality by making specific portions of the retention structure flexible where gap reduction is needed, while maintaining rigidity in other portions for structural support. This localized flexibility allows the system to achieve both thermal efficiency and structural strength by applying the right property in the right location.
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 enhances thermal conductivity by minimizing gaps between the thermal exchange plate and battery array, reducing the need for additional thermal interface materials and maintaining efficient thermal transfer.
Implementation Method 1
The conforming bracket includes platforms configured to flex as the conforming bracket is secured. The flexing facilitates aligning an area of the conforming bracket with a thermal exchange plate.
Implementation Method 2
a thermal exchange plate used to cool the arrays, heat the arrays, or both
Implementation Method 3
a thermal exchange plate used to cool the arrays, heat the arrays, or both
Data Source
AI summary
A battery pack retention assembly includes, among other things, a conforming bracket that secures a battery array within a battery pack. The conforming bracket includes platforms that flexes as the conforming bracket is secured. The flexing facilitates aligning an area of the conforming bracket with a thermal exchange plate. A battery pack retention method includes, among other things, flexing a conforming bracket to reduce a gap between the battery array and a thermal exchange plate. The flexing occurs when securing a battery array to within a battery pack.