Multi-layer Heat Exchanger for Battery Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat exchanger components for electrical energy storage in vehicles require separate and complex applications of insulating materials and additional heating components, leading to increased costs, weight, and space constraints, while also being inefficient in thermal management.
Innovation Solution
A multi-layer heat exchanger component with a carrier material, such as fiber-reinforced plastic, where each layer has a specific function, including electrical insulation and temperature control, allowing for direct coupling with the energy storage device and optimized heat transfer, eliminating the need for separate insulation and heating components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating layers and heating components are applied to cooling plates, then electrical insulation and temperature control are achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the insulating layer and heating component into a single integrated heat exchanger component. The multi-layer structure includes an insulating layer (3) and a functional layer (4) with heating elements, fluid channels, and temperature control features all merged into one component that directly couples with the battery cell housing, eliminating the need for separate application steps.
Solution Approach 2:
The heat exchanger component performs multiple functions simultaneously: electrical insulation through the insulating layer, cooling through fluid channels, and heating through integrated heating elements. This multi-functional design replaces what would traditionally require separate components for each function.
2Reliability
If thin plastic films or silicone coatings are applied for insulation, then electrical insulation is provided, but production costs and processing complexity increase
Solution Approach 1:
The insulating layer is pre-integrated into the heat exchanger component during its manufacturing process rather than being applied separately to the cooling plate later. This preliminary integration eliminates the need for subsequent insulation application steps, reducing processing complexity and costs.
3Adaptability or versatility
If additional heating elements and insulation layers are added, then temperature control capability is improved, but available installation space is reduced
Solution Approach 1:
The heating elements, fluid channels, and insulating layers are nested within the multi-layer structure of the heat exchanger component itself. The functional layer contains heating elements and fluid channels that are integrated within the layered construction, allowing all temperature control components to occupy the same spatial envelope as the insulation layer rather than requiring additional external space.
4Temperature
If metallic or electrically conductive materials are used for cooling plates, then thermal conductivity is improved, but electrical insulation requirements increase
Solution Approach 1:
The heat exchanger component uses a composite multi-layer structure where the functional layer can be made of thermally conductive material for efficient heat transfer, while the insulating layer provides electrical isolation. This composite construction allows the system to benefit from high thermal conductivity where needed while maintaining electrical insulation where required.
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 design reduces manufacturing complexity and costs, enhances thermal management efficiency, and provides a compact, lightweight solution with improved heat transfer capabilities, while allowing for flexible design and functionality adjustments.
Implementation Method 1
a first layer (3) which acts as an electrical insulator
Implementation Method 2
a second layer (4) which enables temperature control, that is to say cooling and/or heating of the electrical energy storage device (18)
Data Source
Figure 1~3c
Figure 4a~6
Figure 7a~9
AI summary
A heat exchanger component of a temperature control system of an electrical energy store may include a carrier material and at least two layers. The at least two layers may include a first layer composed of an electrically insulating material and a second layer that may facilitate temperature control via at least one of cooling and heating the electrical energy store.