Flexible Cooling Plate with Turbulent Flow Support for Battery Cells
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Solution Overview
Problem
Existing cooling plates for traction battery cells fail to provide reliable temperature control due to inadequate turbulence in the coolant flow and limited flexibility in thermal contact, leading to inefficient heat transfer and mechanical stress.
Innovation Solution
A cooling plate design featuring a flexible cover and supporting elements within a flow chamber that increases coolant turbulence and allows for improved thermal and mechanical contact with the battery cell, enhancing temperature control and tolerance equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible cover is used to make thermal contact with the battery cell, then thermal contact capability is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent employs a flexible cover made of elastomeric material that can deform to conform to the battery cell surface, ensuring complete thermal contact. The flexibility allows the cover to adapt to manufacturing tolerances and surface irregularities while maintaining stable mechanical connection through elastic recovery forces.
2Productivity
If supporting elements are added to increase turbulence, then cooling capacity is improved, but device complexity increases
Solution Approach 1:
The patent utilizes the hydraulic action of the flowing coolant itself to create turbulence through supporting elements positioned in the flow chamber. The coolant flow pattern, velocity, and interaction with supporting elements generate eddies and mixing without requiring external mechanical agitators or complex control systems.
Solution Approach 2:
The supporting elements are passively activated by the coolant flow, which automatically adjusts the turbulence level based on the flow rate. The system self-regulates the mixing intensity through the interaction between flowing coolant and fixed supporting structures, eliminating the need for active control mechanisms.
3Manufacturing precision
If the cover is expanded by internal pressure to equalize tolerances, then thermal contact uniformity is improved, but regions with fastening webs cannot expand
Solution Approach 1:
The patent divides the cover into multiple expansion zones separated by fastening web regions. The flexible cover can expand in areas not constrained by webs, while the web regions provide structured attachment points. This segmentation allows differential expansion that maintains thermal contact in expandable regions while providing stable fastening at web locations.
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 design achieves improved temperature control and mechanical stability by creating turbulent coolant flow and accommodating surface unevenness, resulting in enhanced heat transfer and extended battery module service life.
Implementation Method 1
for increasing the turbulence in the coolant flowing through the flow chamber
Implementation Method 2
a laminar flow which is formed within the flow chamber by the coolant
Implementation Method 3
making thermal contact with the at least one battery cell
Implementation Method 4
for controlling the temperature of at least one battery cell
Data Source
AI summary
A cooling plate (10) for controlling the temperature of at least one battery cell, in particular for a traction battery, having a frame (12), which forms a flow chamber (16) for a coolant to flow through, and a cover (14) of flexible design which delimits the flow chamber (16) in an at least partially fluid-tight manner and is provided for making thermal contact with the at least one battery cell. It is proposed that the cooling plate (10) has at least one supporting element (30), which is arranged within the flow chamber (16) and around which coolant can flow, for increasing the turbulence in the coolant flowing through the flow chamber (16) and for supporting the at least one battery cell, which supporting element makes mechanical contact with the cover (14) of flexible design.