Counter-holder device for battery module thermal interface
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Solution Overview
Problem
Conventional thermally conductive pastes and gap fillers used in battery modules require high forces for distribution, leading to elastic or plastic deformation, increased material and weight costs, and reduced thermal conductivity due to excessive paste usage, which is undesirable for high-voltage batteries in electric or hybrid vehicles.
Innovation Solution
A method involving a counter-holder device that supports the cooling device during pressing, allowing high press-on forces without curvature, enabling homogeneous distribution of a thin thermally conductive component for efficient heat dissipation, reducing material and weight while maintaining effective thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermally conductive pastes are used to improve thermal connection between battery module and cooling device, then thermal conductivity is improved, but very large forces are required for distribution which cause elastic or plastic deformation
Solution Approach 1:
The patent changes the physical state of the thermally conductive material from a viscous paste to a solid component with lower viscosity characteristics. This parameter change allows the material to be distributed with significantly reduced pressing forces while still achieving effective thermal connection between the battery module and cooling device.
Solution Approach 2:
The patent employs a solid thermally conductive component that can be compressed to reduce voids and improve thermal contact. The component's structure allows it to conform to surface irregularities when compressed, providing effective thermal connection without requiring the high forces needed for viscous pastes.
2Ease of operation
If larger quantity of thermally conductive paste is provided to achieve sufficient distribution with lower press-on forces, then ease of operation is improved, but weight and costs increase and thermal conductivity deteriorates
Solution Approach 1:
By changing the material from a viscous paste to a solid component with optimized mechanical properties, the patent achieves easy distribution with reduced pressing forces while using minimal material quantity. This eliminates the need to increase material quantity to reduce operating forces, thereby avoiding the associated weight penalty.
Solution Approach 2:
The solid thermally conductive component can be precisely formed and positioned, allowing for optimal material placement without waste. The component replicates the ideal thermal path geometry, ensuring efficient heat transfer with minimal material usage.
3Reliability
If shape-stable formation of battery housing and battery modules is used to resist deformation under pressing forces, then reliability is improved, but material expense and weight increase
Solution Approach 1:
The patent changes the viscosity parameter of the thermally conductive material to a lower state, which directly reduces the pressing forces required during assembly. This force reduction eliminates the need for over-engineered, heavy structural designs, allowing for optimized, lighter battery housing and module constructions that maintain sufficient reliability under the reduced loading conditions.
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 method allows for efficient and homogeneous heat dissipation from battery modules to the cooling device, reducing weight and costs, and preventing damage to the cooling device, while maintaining high thermal conductivity, thus optimizing the arrangement and cooling efficiency of battery modules in battery housings.
Implementation Method 1
a thermally conductive component is placed on the first side of the cooling device, at least in the predetermined module placement area... for thermal connection during installation into a battery housing... thermally dissipation from the battery module to the cooling device is improved
Data Source
AI summary
A method for arranging at least one battery module and at least one part of a battery housing having a cooling device, which is arranged on a side of the part of the battery housing and which has a predetermined module placement area. In doing so, a thermally conductive component is placed on the cooling device, at least in the predetermined module placement area, and the at least one battery module is inserted in the module placement area and pressed against the thermally conductive component in a pressing direction (R) extending in the direction of the cooling device. Before the pressing, a counter-holder device is arranged on the cooling device, which supports the cooling device during pressing of the at least one battery module in the predetermined module placement area, opposite the pressing direction (R).