Split Thermal Fin Battery Frames for Lower TIM Usage
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Solution Overview
Problem
Existing battery packs in electrified vehicles require significant amounts of thermal interface material (TIM) to enhance thermal conductivity between thermal fins and heat exchanger plates, which is costly and complex.
Innovation Solution
The use of split thermal fin designs within array frames that reduce the need for TIM by ensuring positive contact between the thermal fin and heat exchanger plate through integrated ridges, protruding fins, or spring inserts, thereby eliminating or minimizing the requirement for additional thermal interface materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal interface material is used to enhance thermal conductivity between thermal fins and heat exchanger plates, then thermal conductivity is improved, but cost and device complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-forming protruding fins on the thermal fin surface before assembly. These protruding fins are designed to automatically engage with corresponding recesses in the heat exchanger plate, ensuring positive mechanical and thermal contact without requiring additional thermal interface materials. This preliminary structuring of the thermal fin resolves the contradiction by establishing effective thermal conductivity through design rather than through added materials.
Solution Approach 2:
The patent implements self-service through the self-aligning and self-contacting mechanism of the protruding fins. During assembly, the protruding fins naturally engage with the heat exchanger plate recesses under their own geometry, creating automatic positive contact. This eliminates the need for external thermal interface materials and reduces device complexity while maintaining effective thermal conductivity through the self-service contact mechanism.
2Temperature
If thermal interface material is used to enhance thermal conductivity, then thermal conductivity is improved, but cost increases
Solution Approach 1:
The protruding fins are pre-formed on the thermal fin during manufacturing, creating an integrated structure that ensures positive contact with the heat exchanger plate. This preliminary structuring eliminates the need for separate thermal interface material purchases and applications, thereby reducing overall manufacturing cost while maintaining effective thermal conductivity through the engineered contact surfaces.
Solution Approach 2:
The self-contacting protruding fin design eliminates the need for additional thermal interface materials, directly reducing material costs. The self-aligning geometry ensures proper contact without requiring complex assembly procedures or specialized materials, thereby reducing both material and labor costs associated with manufacturing while preserving effective thermal conductivity.
3Device complexity
If split thermal fin design with positive contact features is used, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The protruding fins and corresponding recesses are pre-formed as integral features of the thermal fin and heat exchanger plate respectively, during the primary manufacturing processes. This preliminary structuring ensures that the contact geometry is built-in rather than added later, reducing assembly complexity while the precision requirements are managed through standard manufacturing tolerances applied during the forming processes.
Solution Approach 2:
The protruding fins incorporate rounded or curved contact surfaces that provide tolerance compensation. The curved geometry allows for slight variations in positioning and alignment while maintaining positive contact, thereby reducing the stringency of manufacturing precision requirements. This curvature approach simplifies the overall device structure while accommodating normal manufacturing tolerances.
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 the amount of thermal interface material needed, simplifies assembly, and lowers costs while maintaining effective thermal conductivity.
Implementation Method 1
a second thermal fin section held within the frame body and received in abutting contact with the first thermal fin section
Data Source
AI summary
Battery pack designs are provided for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.