Integrated Cooling Fin and Frame for Battery Pack Thermal Management
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Solution Overview
Problem
Battery packs face issues with dimensional variation and arc flashing due to sliding components, which expose cell edges to cooling fins, leading to potential electrical hazards.
Innovation Solution
An integrated cooling fin and frame design that includes a cooling fin with channels adjacent to its edges, covered by a frame with openings for fluid circulation, providing electrical isolation and improved heat management, thus eliminating the need for additional sealing and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate cooling fins and frames are used, then thermal management and structural support are provided, but dimensional variation increases and arc flashing risk occurs due to component sliding
Solution Approach 1:
The patent combines the cooling fin and frame into a single integrated component. The frame structure incorporates cooling fins that are directly attached to it, eliminating the need for separate cooling fin components. This integration prevents relative sliding between components, thereby eliminating the risk of arc flashing while maintaining effective thermal management through the integrated cooling fins.
2Temperature
If separate cooling fins and frames are used, then thermal management and structural support are provided, but dimensional variation increases due to component sliding
Solution Approach 1:
The frame and cooling fins are merged into a single integrated component manufactured as one piece. This eliminates dimensional variation caused by relative sliding between separate components, while the integrated structure maintains all necessary cooling functions through the incorporated cooling fins.
3Reliability
If integrated cooling fin and frame design is used, then arc flashing risk is reduced and assembly is simplified, but manufacturing complexity increases
Solution Approach 1:
The integration of cooling fins into the frame creates a single component that eliminates assembly steps and prevents arc flashing. While the integrated design simplifies assembly, the manufacturing process becomes more complex as it requires forming an integrated structure with both frame and cooling fin features in one manufacturing operation.
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 integrated cooling fin and frame design reduces the risk of arc flashing, enhances thermal management, and simplifies the assembly process by providing electrical isolation and improved pressure distribution within the battery cell stack.
Implementation Method 1
a cooling fin having a cooling channel adjacent to at least one edge, the cooling channel having an inlet and an outlet
Implementation Method 2
a fluid manifold connected to the cooling channel inlet and outlet for circulating fluid to the cooling channel
Data Source
AI summary
An integrated cooling fin and frame is described. The integrated cooling fin and frame includes a cooling fin having a cooling channel adjacent to at least one edge, the cooling channel having an inlet and an outlet; and a frame around the cooling fin and covering the edges of the cooling fin, the frame having an opening for the inlet and outlet of the cooling channel. A battery pack containing the integrated cooling fin and frame and a method of making the integrated cooling fin and frame are also described.