Extruded Battery Tray Cooling for EV Heat Dissipation
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Solution Overview
Problem
Existing rechargeable energy storage systems in vehicles face challenges in efficiently managing heat dissipation from battery cells and electric motors, leading to potential performance degradation and safety risks.
Innovation Solution
A vehicle chassis-mounted extruded aluminum tray assembly with integrated liquid coolant passages and air cooling fins, connected to a liquid coolant system that cools both battery cells and electric motors, while using thermal isolation materials to prevent heat transfer to the battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid coolant passages are integrated into the aluminum tray assembly, then cooling efficiency of battery cells and electric motors is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple cooling functions into a single integrated aluminum tray assembly. The tray simultaneously serves as a structural support for battery cells and as a coolant distribution system with integrated passages. This merging of structural and thermal management functions improves cooling efficiency while managing device complexity through consolidation rather than addition of separate systems.
Solution Approach 2:
The aluminum tray assembly performs multiple functions: it provides structural support for battery cells, serves as a coolant distribution manifold with integrated passages, and acts as a mounting surface for electric motors. This multi-functionality allows a single component to address both mechanical support and thermal management needs, improving overall system efficiency.
2Reliability
If thermal isolation materials are used to prevent heat transfer to battery cells, then battery safety is improved, but device complexity increases
Solution Approach 1:
The patent applies thermal isolation materials specifically at locations where heat transfer poses a risk to battery cells, such as between the electric motor mounting and the battery cell supports. This localized application of insulation provides targeted protection for battery safety without requiring complete thermal isolation throughout the entire assembly, thereby managing device complexity.
3Productivity
If extruded aluminum tray assembly with integrated passages is used, then manufacturing efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The aluminum tray assembly is designed as an extruded structure with integrated coolant passages formed during the extrusion process. This segmentation of the manufacturing approach allows the complex shaped tray with internal passages to be produced in a single continuous extrusion operation, improving manufacturing efficiency while the extrusion process itself maintains consistent dimensional precision.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (separate tray, separate coolant lines, separate mounting brackets) with a single extruded aluminum structure that integrates all these functions. The extrusion process substitutes for multiple machining and assembly operations, improving manufacturing efficiency while the tooling-based extrusion process ensures consistent precision.
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
Effectively cools battery cells and electric motors, reducing thermal stress and enhancing system performance and safety by maintaining optimal operating temperatures.
Implementation Method 1
liquid coolant passages extending through the aluminum tray assembly
Implementation Method 2
air cooling fins extending from a bottom of the extruded aluminum tray assembly
Implementation Method 3
air cooling fins extending from a bottom of the extruded aluminum tray assembly
Implementation Method 4
a thermal conductive material for transferring heat between the plurality of battery cells and the extruded aluminum tray
Data Source
AI summary
A vehicle includes a vehicle chassis supported by four wheels. At least one electric motor provides drive torque to at least one of the four wheels. A rechargeable energy storage system is supported by the vehicle chassis and provides electricity to the electric motor. The rechargeable energy storage system includes a housing and a plurality of battery cells disposed within the housing. A base of the housing includes an extruded aluminum tray assembly having liquid coolant passages extending through the aluminum tray assembly and air cooling fins extending from a bottom of the extruded aluminum tray assembly.