Seamless Shrink-Wrap Battery Cell Thermal Interface
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Solution Overview
Problem
Electrically isolating battery cells in electric vehicles while providing adequate cooling is challenging due to the difficulty in simultaneously isolating and cooling these cells effectively.
Innovation Solution
A method involving the use of seamless shrink-wrap material to cover the sides of battery cells, ensuring a uniform and seamless interface with a cold plate for efficient thermal transfer, while using seams only on laterally outward-facing sides to maintain electrical isolation and prevent short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shrink-wrap material is used to cover battery cell sides for electrical isolation, then electrical isolation is improved, but thermal transfer efficiency deteriorates due to the insulating nature of the wrap material
Solution Approach 1:
The patent applies different wrap configurations to different locations: seamless wrap at the cold plate interface for thermal efficiency, and seam-containing wrap at lateral sides for electrical isolation. This local differentiation resolves the contradiction by optimizing each location for its primary function.
Solution Approach 2:
The shrink-wrap is segmented into functional zones: a seamless portion covering the cold plate interface area and separate portions covering lateral sides. This segmentation allows each zone to serve its specific purpose without compromising the other.
2Temperature
If seamless shrink-wrap is used at the cold plate interface, then thermal transfer is improved, but manufacturing complexity increases due to the need for precise wrap placement and sealing
Solution Approach 1:
The wrap is divided into modular sections that can be independently applied and sealed. The seamless portion is applied as a single continuous piece over the cold plate interface, while lateral sides receive separate wrap portions, simplifying the manufacturing process while maintaining thermal efficiency.
Solution Approach 2:
The cold plate structure itself serves as an intermediary that guides and positions the seamless wrap during application, ensuring proper alignment and contact without requiring complex external positioning fixtures.
3Reliability
If shrink-wrap covers all sides of the battery cell, then electrical isolation is maximized, but cooling efficiency deteriorates due to the insulating barrier between the cell and cold plate
Solution Approach 1:
The patent implements local quality by applying seamless wrap only at the cold plate interface where thermal contact is critical, while using separate wrap portions with seams at lateral sides where electrical isolation is the primary concern. This resolves the contradiction by optimizing each region for its dominant function.
Solution Approach 2:
The shrink-wrap system is segmented into a seamless thermal interface portion and separate electrical isolation portions, allowing the thermal path to remain direct and efficient while electrical isolation is maintained through the segmented wrap structure.
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 approach enhances thermal energy transfer, reduces the risk of short-circuiting, and ensures effective electrical isolation, thereby improving the performance and lifespan of battery cells by maintaining uniform cooling and electrical insulation.
Implementation Method 1
heating the shrink-wrap material after the joining to shrink the shrink-wrap material to the battery cell
Implementation Method 2
The seamless interface promotes efficient thermal energy transfer between the battery cell and the cold plate
Data Source
AI summary
An example battery cell shrink-wrapping method includes covering a side of a battery cell with a section of a shrink-wrap material. The side interfaces with a cold plate when the battery cell is within a battery pack.