Mid-tray Battery Pack Thermal Management and Sealing

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Solution Overview

Problem

Conventional battery packs for electrified vehicles face challenges in effectively managing heat and sealing for second-tier battery arrays, often requiring complex designs with internal coolant joints that increase costs and complexity.

Innovation Solution

The integration of a mid-tray structure within the battery pack that serves as a supporting, sealing, and thermal management system for second-tier battery arrays, featuring an internal cooling circuit and thermal interface material, with coolant ports located externally to eliminate the need for internal coolant joints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery packs use separate cooling and sealing structures for second-tier battery arrays, then thermal management and sealing functions can be provided, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the cooling structure and sealing structure into a single integrated mid-tray component. The mid-tray includes cooling channels formed within its body and sealing surfaces that mate with the battery pack housing, eliminating the need for separate cooling plates and sealing gaskets. This integration reduces the number of parts, simplifies assembly, and lowers manufacturing costs while maintaining effective thermal management and sealing functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mid-tray structure serves multiple functions simultaneously: it provides structural support for second-tier battery arrays, conducts thermal management through integrated cooling channels, and provides sealing through its mating surfaces with the housing. This multi-functional design eliminates the need for separate dedicated components for each function, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If internal coolant joints are used in conventional battery packs, then cooling circuits can be established, but manufacturing complexity and assembly difficulty increase

Engineering Contradiction:

Improvecooling circuit functionalityVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling circuit is integrated directly into the mid-tray structure with cooling channels formed as part of the single component. Coolant flow paths are established through the mid-tray body itself, eliminating the need for separate internal coolant joints, gaskets, or additional connection components. This integration simplifies manufacturing and assembly while ensuring reliable cooling circuit functionality.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple separate components are used for supporting, cooling, and sealing, then each function can be optimized independently, but device complexity and cost increase

Engineering Contradiction:

Improvefunctional optimizationVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mid-tray is designed as a universal component that performs supporting, cooling, and sealing functions simultaneously. The structure includes battery array mounting surfaces for support, integrated cooling channels for thermal management, and sealing surfaces for fluidtight enclosure. This multi-functional design maintains functional optimization while reducing the total number of components and simplifying the overall system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This configuration enhances thermal management, reduces complexity, and lowers costs by integrating thermal and sealing functions into a single structure, improving the efficiency and lifespan of battery cells while maintaining effective moisture and coolant management.

Implementation Method 1

an internal cooling circuit disposed inside the mid-tray and configured to thermally manage the second battery array

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The mid-tray includes a plurality of cooling channels formed within the mid-tray

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

a thermal interface material (TIM) disposed between the second battery array and the mid-tray

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11335963B2Traction battery packs with second tier integrated supporting, thermal, and sealing structures

Publication Date: 2022.05.17 FORD GLOBAL TECH LLC

AI summary

This disclosure details exemplary battery pack designs, such as those designed for use within electrified vehicles. Exemplary battery packs may include an enclosure assembly and a plurality of battery arrays housed inside the enclosure assembly. The enclosure assembly may include a mid-tray that is configured for supporting, cooling/heating, and sealing second tier battery arrays. The configuration of the mid-tray allows coolant joints to be eliminated inside of the battery pack.