Divider Fin Structure for Battery Pack Thermal Compartmentalization

Solution Overview

Problem

Existing traction battery packs face challenges in structural integrity and thermal management, as thermal events can propagate across battery cells due to lack of effective compartmentalization and structural coupling between enclosure components.

Innovation Solution

The use of divider fins with upper and lower fin portions configured to interface with enclosure structures, along with a mid-fin portion between battery cells, which are secured using fasteners like adhesives or weld beads, and optionally include insulating or heat absorption materials to compartmentalize the cell stack and enhance structural coupling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are arranged in a compact stack to increase energy density, then productivity and space utilization are improved, but thermal propagation between cells increases and structural integrity decreases

Engineering Contradiction:

Improveenergy densityVSAvoidthermal propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The battery pack is segmented into discrete compartments using divider fins positioned between adjacent battery cells. These fins create physical barriers that divide the cell stack into isolated sections, preventing thermal events from propagating across the entire pack while maintaining compact arrangement for high energy density.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Divider fins serve as intermediary structures positioned between battery cells. These fins act as thermal barriers and structural couplers that mediate between the need for compact cell arrangement and the need to prevent thermal propagation, blocking heat transfer while maintaining structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If enclosure components are designed as separate parts for ease of assembly, then ease of manufacture is improved, but structural integrity and structural coupling between components deteriorate

Engineering Contradiction:

Improveassembly easeVSAvoidstructural coupling

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The divider fin integrates multiple functions into a single component: it provides thermal compartmentalization, structural coupling between upper and lower enclosure components, and mechanical support for battery cells. This merging eliminates the need for separate structural couplers while maintaining ease of assembly and enhancing structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The divider fin is designed as a multi-functional component that simultaneously performs thermal barrier functions, structural coupling functions, and mechanical support functions. This universal component replaces multiple separate parts, maintaining manufacturing ease while improving structural integrity through integrated design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If divider structures are added to compartmentalize battery cells and prevent thermal propagation, then thermal management is improved, but device complexity increases

Engineering Contradiction:

Improvethermal propagationVSAvoidstructural complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The divider fin is designed as a multi-functional component that simultaneously performs thermal barrier functions, structural coupling functions, and mechanical support functions. This universal component replaces multiple separate parts, maintaining manufacturing ease while improving structural integrity through integrated design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The divider fin integrates multiple functions into a single component: it provides thermal compartmentalization, structural coupling between upper and lower enclosure components, and mechanical support for battery cells. This merging eliminates the need for separate structural couplers while maintaining ease of assembly and enhancing structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

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 divider fins effectively compartmentalize the battery cell stack, reduce thermal propagation, and increase the structural integrity of the traction battery pack by structurally joining upper and lower enclosure structures, thereby enhancing the pack's ability to manage thermal events and maintain stability during battery operations.

Implementation Method 1

The inner layer includes an insulating material, a compliant material, a heat absorption material, or combinations thereof

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The inner layer includes an insulating material, a compliant material, a heat absorption material, or combinations thereof

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 3

The first fastener and the second fastener each include an adhesive or a weld bead

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 4

The first fastener and the second fastener each include an adhesive or a weld bead

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20240079711A1Structural divider fins for use within traction battery packs

Publication Date: 2024.03.07 FORD GLOBAL TECH LLC

AI summary

Divider fins are disclosed for traction battery packs. An exemplary divider fin may be arranged between adjacent battery cells of a battery cell stack. The divider fin may include an upper fin portion configured to interface with an enclosure cover, and a lower fin portion configured to interface with an enclosure tray or a heat exchange plate. The divider fin may be configured to compartmentalize the cell stack, structurally join upper and lower battery structures, contain thermal energy during battery thermal events, etc.