Liquid Cooling Manifold with Dual Layer Thermal Interface
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Solution Overview
Problem
Existing battery cooling systems face challenges in manufacturability and cost due to labor-intensive processes in inserting thermally conductive materials between batteries and coolant tubes, which affects the efficiency and production of battery packs, particularly in preventing thermal runaway in unstable secondary battery chemistries.
Innovation Solution
A liquid cooling manifold assembly with a dual layer thermal interface, comprising a compressible inner layer and a dielectric outer layer, is used to improve heat transfer efficiency and reduce production costs by minimizing the need for electrically insulating coatings on metal coolant channels and allowing for easier assembly between battery rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermally conductive material is inserted between the cooling tube and the batteries to improve heat removal efficiency, then the thermal management performance is improved, but the production process becomes labor-intensive and costly
Solution Approach 1:
The patent combines the cooling tube, thermal interface material, and electrical insulation function into a single integrated assembly. The extruded cooling tube includes integrated fins and is pre-filled with phase change material, eliminating the need for separate insertion steps and combining multiple functions into one manufacturable component.
Solution Approach 2:
The thermal interface material and phase change material are pre-positioned within the cooling tube structure during manufacturing, before the cooling tube is installed in the battery pack. This preliminary action eliminates the need for labor-intensive manual insertion during assembly and ensures proper positioning and contact with the battery terminals.
2Temperature
If metal coolant channels are used to improve thermal conductivity, then heat transfer efficiency is improved, but electrical interference with the batteries occurs
Solution Approach 1:
The patent introduces phase change material as an intermediary substance between the metal cooling tube and the battery terminals. This material layer maintains thermal contact while providing electrical insulation, allowing the metal tube to retain its superior thermal conductivity without causing electrical interference with the battery cells.
Solution Approach 2:
The cooling assembly uses a composite structure combining metal coolant channels with phase change material and thermal interface materials. This composite approach allows the metal to provide thermal conductivity while the phase change material provides both thermal management and electrical insulation functions.
3Object-affected harmful factors
If electrically insulating coatings are applied to metal coolant channels to prevent electrical interference, then electrical safety is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
Instead of coating the metal surface, the patent uses phase change material as an intermediary that naturally fills the interface between the metal cooling tube and battery terminals. This material provides electrical insulation while maintaining intimate thermal contact through its conformal nature and phase change properties, avoiding the thermal barrier effect of traditional coatings.
Solution Approach 2:
The patent changes the physical state parameters of the thermal interface material by using phase change material that transitions between solid and liquid states. This allows the material to adapt its properties - remaining solid for structural integrity and electrical insulation, but becoming liquid to fill gaps and maintain thermal contact - thereby achieving both electrical safety and heat transfer efficiency.
4Temperature
If complex assembly processes are used to ensure proper thermal contact, then thermal management performance is improved, but production time and costs increase
Solution Approach 1:
The cooling tubes are pre-assembled with phase change material and thermal interface materials during manufacturing, ensuring proper thermal contact is established before installation. This preliminary preparation eliminates the need for complex assembly procedures during battery pack production and ensures consistent thermal performance.
Solution Approach 2:
The phase change material automatically adjusts to the battery terminal surfaces through its phase change properties, self-aligning and conforming to ensure optimal thermal contact without requiring precise manual positioning or complex alignment procedures. The material essentially services its own positioning function.
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 dual layer thermal interface enhances heat removal efficiency, reduces production time and costs, and improves the packing density of battery packs while preventing electrical interference, thus addressing the challenges of thermal management and manufacturability in battery cooling systems.
Implementation Method 1
The inner material layer of the dual layer thermal interface, and that which is adjacent to the coolant channel portion of the assembly, is comprised of a compressible material with a modulus of compressibility of less than 3 MPa
Implementation Method 2
The outer material layer of the dual layer thermal interface, and that which is adjacent to the cells of the battery pack, is comprised of a dielectric material with a breakdown voltage of greater than 500 VDC
Implementation Method 3
a liquid cooling manifold assembly for use in the thermal management system of a battery pack. The liquid cooling manifold assembly includes a coolant channel portion through which the coolant channels run
Data Source
AI summary
A liquid cooling manifold assembly for use in the thermal management system of a battery pack is provided. The liquid cooling manifold assembly includes a coolant channel portion through which the coolant channels run, and a dual layer thermal interface interposed between the coolant channel portion and the cells of the battery pack. The outer material layer of the dual layer thermal interface is comprised of an electrically non-conductive, high dielectric material that is preferably tear resistant, deformable and has a high tensile strength and a relatively low surface friction. The inner material layer of the dual layer thermal interface is comprised of a highly compressible material.