Lattice Battery Pouch Cooling Structure for Uniform Heat Transfer
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Solution Overview
Problem
Existing thermal management systems for battery packs in electric vehicles are inadequate for efficiently cooling battery packs, especially in long-distance travel, leading to potential overheating issues.
Innovation Solution
A thermal management structure comprising a plurality of lattice-structured walls manufactured via additive manufacturing, which includes outer, intermediate, and bottom walls in heat transfer relationships with battery pouches, facilitating efficient heat conduction and fluid flow for effective cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermal management systems are used for battery packs, then the structure is simple and easy to manufacture, but the cooling efficiency is insufficient leading to overheating issues
Solution Approach 1:
The patent employs lattice structures with porous characteristics that provide high surface area to volume ratio, enabling enhanced heat transfer between the battery packs and cooling fluid while maintaining structural integrity. The porous lattice design allows coolant to flow through multiple pathways, significantly improving cooling efficiency compared to conventional solid walls.
Solution Approach 2:
The invention transitions from conventional two-dimensional cooling plates to three-dimensional lattice structures that extend cooling surfaces in multiple spatial dimensions. This dimensional transformation creates numerous internal flow channels and heat transfer surfaces, dramatically increasing the effective cooling area without proportionally increasing the overall structure volume.
2Temperature
If lattice structures are used to enhance heat transfer, then thermal management efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes additive manufacturing technology that enables the fabrication of complex lattice structures by changing manufacturing parameters such as lattice cell size, wall thickness, and pattern density. These parameter variations allow optimization of heat transfer characteristics while maintaining manufacturability through digital modeling and direct 3D printing processes.
Solution Approach 2:
The invention replaces traditional mechanical manufacturing methods (such as machining, molding, or assembling multiple components) with additive manufacturing processes. This substitution eliminates the need for complex tooling, toolpaths, and assembly operations, enabling direct fabrication of intricate lattice structures from digital models, thereby reducing manufacturing complexity despite the geometric complexity of the final product.
3Temperature
If multiple walls with lattice structures are used for comprehensive cooling, then thermal management coverage increases, but the weight of the structure increases
Solution Approach 1:
The lattice structures function as porous materials that provide extensive cooling surface area within a compact volume. The porous architecture allows the structure to achieve comprehensive thermal management coverage across multiple battery pack surfaces while maintaining low weight, as the lattice walls are significantly thinner and less material-intensive than conventional solid cooling plates.
Solution Approach 2:
The patent employs lattice structures that can be fabricated from high-strength, thermally conductive materials or composite materials optimized for thermal management applications. These materials provide enhanced strength-to-weight ratios and thermal conductivity, enabling the structure to achieve comprehensive cooling coverage while minimizing weight compared to conventional solid metal cooling plates.
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 structure provides enhanced thermal management by directly transferring heat from battery pouches to the walls and directing coolant flow for uniform cooling, maintaining optimal battery performance and safety.
Implementation Method 1
Each of the first and second outer walls includes a first lattice structure and the intermediate wall includes a second lattice structure... in heat transfer relationship with respective outer side of the battery pouch... in a heat transfer relationship with an inner side of the battery pouch
Data Source
AI summary
A thermal management structure for a battery pouch of a vehicle battery pack includes a plurality of walls. The plurality of walls include a pair of outer walls and an intermediate wall. Each outer wall is in a heat transfer relationship with a respective outer side of the battery pouch. The intermediate wall is disposed between the pair of outer walls and is in a heat transfer relationship with an inner side of the battery pouch. Each of the outer walls includes a first lattice structure and the intermediate wall includes a second lattice structure.