Flexible Bladder Thermal Plate for Battery Cell Arrays
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Solution Overview
Problem
Existing thermal management systems for high voltage batteries in vehicles face inefficiencies in heat transfer due to uneven contact between thermal plates and battery cell arrays, leading to reduced thermal management effectiveness and potential battery performance degradation.
Innovation Solution
A traction battery thermal plate assembly featuring a flexible bladder with dielectric properties, which expands or contracts to conform to the battery cell array surface, enhancing contact and heat transfer, and includes a frame with ribs to direct thermal fluid flow and support the array, along with an inlet port system to control fluid flow and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid thermal plate is used, then structural stability is maintained, but contact uniformity with battery cells deteriorates due to manufacturing tolerances and cell dimensional variations
Solution Approach 1:
The patent applies the dynamics principle by transforming the rigid thermal plate into a flexible bladder that can dynamically adapt its shape. The bladder is filled with fluid under pressure, allowing it to expand and conform to the actual surface geometry of the battery cells, thereby achieving uniform contact despite manufacturing tolerances and cell dimensional variations while maintaining structural stability through the pressurized fluid system
Solution Approach 2:
The patent applies parameter changes by modifying the physical state of the thermal management component from rigid to flexible through fluid pressurization. By controlling the fluid pressure parameter, the bladder can adjust its volume and shape to match the battery cell array configuration, ensuring consistent thermal contact across all cells while maintaining overall structural integrity
2Loss of energy
If thermal plate directly contacts all battery cells, then heat transfer efficiency is maximized, but electrical insulation between thermal management system and battery cells becomes problematic
Solution Approach 1:
The patent applies the intermediary principle by introducing the flexible bladder as a mediating component between the thermal management system and the battery cells. The bladder material itself provides electrical insulation while its fluid interior maintains thermal contact with the cells through conduction, thus achieving both heat transfer efficiency and electrical insulation simultaneously
Solution Approach 2:
The patent applies composite materials by using a bladder constructed from electrically insulating material that can flex and conform to battery cell surfaces. This composite structure combines the insulating properties necessary for electrical safety with the thermal conductivity required for efficient heat transfer, eliminating the need for additional insulation layers
3Loss of energy
If thermal fluid flow rate is increased, then heat removal capability is improved, but system complexity increases due to need for flow control mechanisms
Solution Approach 1:
The patent applies merging by combining the thermal plate structure with integrated flow control features. The thermal management system incorporates constrictors or flow control elements directly within the thermal plate or bladder structure, allowing heat removal capability to be enhanced through increased fluid flow rate while avoiding the need for separate, complex external flow control mechanisms
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 flexible bladder assembly improves heat transfer efficiency by eliminating contact deficiencies and maintaining consistent thermal communication, potentially extending battery life and performance by ensuring uniform thermal management.
Implementation Method 1
The flexible bladder is configured to be filled with a fluid such that the bladder contacts the array to transfer heat between the array and fluid
Implementation Method 2
The flexible bladder is configured to adjust between a first and second volume... The flexible bladder is configured to expand in response to an increase in a pressure of the thermal fluid flow
Implementation Method 3
The flexible bladder may be of a material with dielectric characteristics such that contents of the bladder are electrically insulated from the battery cells
Data Source
AI summary
A traction battery thermal plate assembly may include a structure having edge portions defining a cavity and configured to support a battery cell array. A flexible bladder may be disposed within the cavity between the structure and array. The flexible bladder may be configured to be filled with a fluid such that the bladder contacts the array to transfer heat between the array and fluid. The assembly may include a frame sized to receive the flexible bladder and configured to support the flexible bladder. An inlet port may be in fluid communication with the flexible bladder and a pump, and may be configured to deliver fluid to the flexible bladder at a pump output rate. The flexible bladder may include ribs defining channels therebetween. The channels may be configured to direct fluid flow along the at least one surface of the battery cell array.