Plastic Heat Sink Geometry for Cooling Cylindrical Battery Cells
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Solution Overview
Problem
Current metal heat sinks used for cooling cylindrical battery cells are expensive, heavy, and inefficient, as they do not effectively address the thermal management needs of electromobility applications.
Innovation Solution
A plastic-based heat sink with an elongated base profile featuring alternating concave and straight regions on its main surfaces, which includes fluid flow channels separated by webs, enhancing cooling efficiency while reducing material costs and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal heat sinks are used for cooling cylindrical battery cells, then good thermal conductivity is achieved, but the weight and material cost significantly increase
Solution Approach 1:
The patent changes the material parameter from metal to plastic, accepting lower thermal conductivity but compensating through geometric optimization. The heat sink features alternating concave and straight regions on its main surfaces, with concave regions on one surface superposed by straight regions on the opposite surface, creating extended heat exchange paths that improve thermal performance despite the inferior material properties.
Solution Approach 2:
The patent introduces a complex three-dimensional surface topology with alternating concave and straight regions. The superposition of concave regions on one main surface by straight regions on the opposite surface creates multiple dimensions of heat exchange, effectively increasing the thermal contact area and heat transfer efficiency without proportionally increasing weight.
2Temperature
If metal heat sinks are used for cooling cylindrical battery cells, then adequate cooling is provided, but material cost and production cost increase
Solution Approach 1:
The patent changes the material parameter from metal to plastic, which has lower material cost and easier manufacturability. The complex surface geometry with alternating concave and straight regions can be efficiently produced using plastic molding techniques, avoiding the expensive machining and assembly processes required for metal heat sinks while maintaining adequate cooling performance.
3Weight of moving object
If plastic is used for heat sink, then weight and cost are reduced, but thermal conductivity decreases
Solution Approach 1:
The patent compensates for plastic's lower thermal conductivity by introducing a multi-dimensional surface structure. The alternating concave and straight regions on the main surfaces, with superposition between opposite surfaces, create extended heat transfer paths that increase the effective heat exchange area and improve thermal performance despite the inferior material properties.
Solution Approach 2:
The heat sink surface is segmented into alternating concave and straight regions, with fluid flow channels separated by webs. This segmentation creates multiple discrete heat exchange zones that work in parallel, improving overall heat transfer efficiency by distributing the thermal load across multiple surfaces and pathways.
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 plastic-based heat sink provides improved cooling performance for cylindrical components by optimizing heat exchange through a larger contact surface and efficient fluid flow, while also reducing the overall weight and cost of the cooling system.
Implementation Method 1
the base profile defines in its interior a plurality of at least two fluid flow channels, which each extend from one longitudinal end of the base profile to the other longitudinal end of the base profile
Implementation Method 2
metal has a good thermal conductivity coefficient
Data Source
AI summary
Disclosed is a device for regulating the temperature of cylindrical components and a cooling system including at least two devices for regulating the temperature of cylindrical components. The device includes an elongate base profile that defines in its interior a plurality of at least two fluid flow channels arranged in series in the transverse direction and are separated by webs. The elongate base profile has main surfaces that each have an alternating sequence of concave regions and straight regions.