Flexible Thermal Fin Battery Array Frame Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrified vehicle battery arrays face challenges in securing and cooling battery cells effectively, with existing solutions failing to provide adequate thermal management and secure mounting mechanisms.
Innovation Solution
A battery array frame design featuring a thermal fin with a flexible leg that adjusts position to enhance heat transfer and a unitary plastic structure with integrated retention features for secure stacking and mounting, including segmented thermal fins and snap arms for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid thermal fin structure is used, then structural strength is improved, but thermal contact adaptability deteriorates
Solution Approach 1:
The thermal fin structure transitions from a static rigid design to a dynamic flexible design, allowing the fin to adapt its shape and contact pressure based on thermal management requirements while maintaining structural integrity through elastic deformation
2Ease of manufacture
If multiple separate components are used for array frames, then ease of assembly is improved, but device complexity deteriorates
Solution Approach 1:
Multiple separate array frame components are merged into a single integrated frame structure with built-in retention features and thermal fin integration, reducing the total number of parts while maintaining ease of assembly through modular battery cell insertion
Solution Approach 2:
The array frame structure performs multiple functions simultaneously: structural support, thermal management through integrated fins, and battery cell retention through built-in features, eliminating the need for separate components for each function
3Temperature
If thermal fin leg is positioned closer to cooling plate, then heat transfer efficiency is improved, but risk of interference with adjacent frames deteriorates
Solution Approach 1:
The thermal fin leg is designed as a flexible element that dynamically adjusts its position and contact pressure with the cooling plate, allowing optimal thermal contact while the flexible nature prevents rigid interference with adjacent frame structures
Solution Approach 2:
The physical state of the thermal fin leg changes from rigid to flexible, allowing it to deform and adapt its position based on thermal requirements while automatically avoiding interference with surrounding components through elastic compliance
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 effectively secures battery cells, improves thermal management by adjusting heat transfer based on the thermal fin's position, and simplifies assembly and handling through flexible and rigid snap arms, ensuring efficient operation and longevity of the battery array.
Implementation Method 1
a thermal fin (66) including a body (74) embedded in the frame body (58) and a leg (72) that extends outside of the frame body
Data Source
AI summary
A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body, and a thermal fin including a body embedded in the frame body and a leg that extends outside of the frame body. The thermal fin is flexible between a first position in which the leg is spaced farther from a surface of the frame body and a second position in which the leg is spaced closer to the surface of the frame body.