Thermal Barrier Assemblies With Internal Cooling for Battery Pack Compartments
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Solution Overview
Problem
Traction battery packs in electrified vehicles face challenges in managing thermal energy levels, which can lead to thermal events and affect the performance and longevity of the battery cells.
Innovation Solution
The implementation of a thermal barrier assembly with an internal coolant circuit and thermally insulating layers to partition the battery cell stack into compartments, effectively managing thermal energy and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal barrier assemblies with internal coolant circuits are implemented, then thermal energy management is improved, but device complexity increases
Solution Approach 1:
The thermal barrier assembly merges multiple functions into a single integrated structure: thermal insulation, structural support, and active cooling. The insulating layers are combined with an internal coolant circuit system, eliminating the need for separate insulation components and cooling plates, thus improving thermal management while controlling overall device complexity.
Solution Approach 2:
The thermal barrier assembly serves multiple purposes simultaneously: it provides thermal insulation to prevent heat propagation, structural support to maintain battery pack integrity, and active cooling through integrated coolant circuits. This multi-functionality addresses thermal energy management needs without requiring additional separate components.
2Reliability
If battery cell stack is partitioned into compartments, then thermal event propagation is reduced, but manufacturing complexity increases
Solution Approach 1:
The battery cell stack is divided into separate compartments using thermal barrier assemblies that act as partitions. This segmentation prevents thermal events from propagating between adjacent cell groups, enhancing safety. The modular partition design allows for standardized manufacturing processes while achieving reliable thermal isolation.
3Temperature
If thermally insulating layers are added, then thermal insulation performance is improved, but weight increases
Solution Approach 1:
The thermal barrier assembly uses composite material structures combining thermally insulating layers with structural support elements and integrated coolant circuits. This composite approach provides effective thermal insulation while distributing weight across multiple functional components, optimizing the weight-to-insulation-performance ratio.
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 thermal barrier assembly effectively manages thermal energy within the traction battery pack, reducing the risk of thermal events and enhancing the structural integrity, thereby improving the performance and longevity of the battery cells.
Implementation Method 1
an internal coolant circuit adapted for directing a coolant through the thermal barrier structure
Implementation Method 2
directing a coolant through the thermal barrier structure
Implementation Method 3
first thermally insulating layer and a second thermally insulating layer
Data Source
AI summary
Multi-functional thermal barrier assemblies may be configured to both manage thermal energy levels inside a traction battery pack and to increase the structural integrity of the traction battery pack. In some implementations, the thermal barrier assembly may include an internal cooling circuit for directing a coolant through a thermal barrier structure of the thermal barrier assembly. The thermal barrier structure may be an extrusion, a pultrusion, or an injection molded part. In other implementations, the thermal barrier assembly may include thermally insulating layers. The thermally insulating layers may be cladding layers that provide an outer skin of the thermal barrier structure.