Spring-Loaded Thermal Plate for Battery Heat Transfer
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Solution Overview
Problem
Current thermal management systems for high voltage batteries in vehicles face inefficiencies in heat transfer due to uneven mating surfaces and structural loads, which can lead to reduced thermal performance and increased production costs.
Innovation Solution
A traction battery thermal plate assembly with a spring assembly that exerts a force against a thermal plate to ensure contact with the battery cell array, utilizing a crimped sheet of material with tabs extending in a wave-like fashion to enhance heat transfer and support structural loads, while maintaining contact even under operational movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid thermal plate is used to ensure structural stability, then strength is improved, but contact uniformity with the battery cell array deteriorates due to uneven mating surfaces
Solution Approach 1:
The patent replaces the rigid thermal plate with a flexible thermal plate that can dynamically adapt its shape to match the contour of the battery cell array. This flexibility allows the plate to maintain uniform contact across uneven surfaces while still providing sufficient structural support for thermal management.
Solution Approach 2:
The patent changes the physical parameter of the thermal plate from rigid to flexible, enabling it to deform and conform to the battery cell array surface. This parameter change resolves the contradiction by allowing the plate to adapt to manufacturing variations while maintaining contact uniformity.
2Reliability
If additional support structures are added to ensure contact between thermal plate and battery array, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent removes the need for additional support structures by extracting the contact adaptation function from the structural support system and integrating it directly into the flexible thermal plate itself. The flexible plate inherently provides both support and contact adaptation without requiring separate components.
Solution Approach 2:
The flexible thermal plate serves multiple functions simultaneously: it provides thermal management, maintains contact with the battery array, and adapts to surface irregularities. This multi-functionality eliminates the need for separate support structures, reducing device complexity while maintaining reliability.
3Temperature
If the thermal plate is made heavier to increase contact force, then heat transfer efficiency is improved, but weight of the system increases
Solution Approach 1:
The patent changes the material parameter of the thermal plate to use high-strength, low-density materials. This allows the plate to maintain sufficient contact force for effective heat transfer while minimizing weight, resolving the contradiction between heat transfer efficiency and system weight.
Solution Approach 2:
The patent employs composite materials for the thermal plate that combine thermal conductivity with flexibility and weight reduction. These composite materials provide the necessary mechanical properties for maintaining contact force without the weight penalty of traditional dense materials.
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 improves heat transfer efficiency and reduces production costs by ensuring consistent contact between the thermal plate and battery cell array, enhancing thermal management and durability.
Implementation Method 1
The spring assembly is configured to exert a force against the plate such that plate contacts the array to transfer heat between the array and the plate
Data Source
AI summary
A traction battery thermal plate assembly may include a structure having edge portions defining a cavity and configured to support a battery cell array, a thermal plate disposed within the cavity and adjacent to the array, and a spring assembly disposed within the cavity between the structure and the plate. The spring assembly may be configured to exert a force against the plate such that plate contacts the array to transfer heat between the array and the plate. The thermal plate disposed within the cavity may be below the array. The spring assembly may include a body defining a plurality of tabs configured to extend outward from a plane defined by the body. The spring assembly may include a base portion and an upper portion configured to support one or more compression springs therebetween.