Multi-Tier Battery Support Structure With Integrated Thermal Exchange
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Solution Overview
Problem
Existing battery array configurations in electrified vehicles require multiple support structures and thermal exchange plates for each tier, leading to complexity and inefficiency in thermal management and maintenance.
Innovation Solution
A support structure that acts as a thermal exchange plate, sandwiched between an upper and lower tier of battery arrays, secures both tiers mechanically and manages thermal energy, eliminating the need for separate support structures and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate support structures and thermal exchange plates are used for each battery tier, then each tier can be independently supported and cooled, but the overall device complexity increases and maintenance becomes more difficult
Solution Approach 1:
The patent combines the support structure and thermal exchange plate into a single integrated component. The support structure includes cooling channels formed within its body, allowing it to simultaneously provide mechanical support for battery tiers and thermal management functions. This eliminates the need for separate support structures and thermal exchange plates for each tier, reducing overall device complexity while maintaining reliable thermal management.
Solution Approach 2:
The support structure is designed to perform multiple functions: it provides mechanical support for mounting battery tiers, serves as a thermal exchange plate with integrated cooling channels for heat dissipation, and acts as a structural framework for the entire battery assembly. This multi-functional design reduces the number of components needed while ensuring both structural integrity and effective thermal management.
2Strength
If multiple separate support structures are used for each battery tier, then each tier has dedicated support, but the quantity of components increases
Solution Approach 1:
Instead of using separate support structures for each battery tier, the patent merges them into a single integrated support structure that can simultaneously support multiple tiers. The support structure includes mounting features and cooling channels designed to accommodate and cool multiple battery tiers, thereby reducing the total number of support structures from multiple individual components to one unified structure.
3Volume of moving object
If battery tiers are closely mounted to maximize space utilization, then vehicle space efficiency improves, but thermal management efficiency deteriorates
Solution Approach 1:
The support structure integrates cooling channels directly within its body, positioned to efficiently remove heat from closely mounted battery tiers. The cooling channels are configured to receive coolant that flows through them, providing active thermal management even when battery tiers are in close proximity. This allows maximum space utilization while maintaining effective heat dissipation through the integrated cooling system.
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 simplifies thermal management, reduces component count, and facilitates easier maintenance by allowing both tiers to be secured to a single support structure, enhancing thermal efficiency and service accessibility.
Implementation Method 1
the support structure is a thermal exchange plate that manages thermal energy of the battery arrays in the upper tier and the battery arrays in the lower tier
Data Source
AI summary
A traction battery assembly according to an exemplary aspect of the present disclosure includes a lower tier of battery arrays, an upper tier of battery arrays, and a support structure disposed between the lower tier and the upper tier. The lower tier is suspended from a downwardly facing side of the support structure. The upper tier is disposed atop an upwardly facing side of the support structure.