Structural Battery Cooling Plate That Cuts Pack Reinforcement
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Solution Overview
Problem
Existing heat exchange plates for battery packs in vehicles require additional structural elements to ensure mechanical strength, which increase manufacturing costs, weight, and CO2 emissions.
Innovation Solution
A dual-plate heat exchange system where one plate is made of a structural material with high mechanical properties and the other plate is made of a material with lower mechanical properties but easier to form, combined with anti-corrosion and brazing layers to maintain structural integrity and reduce the need for additional structural components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional structural elements (beams, crossmembers, protectors) are added to ensure mechanical strength of the battery pack, then the mechanical strength and reliability are improved, but the manufacturing cost, weight, and CO2 emissions increase
Solution Approach 1:
The patent merges the structural support function with the heat exchange plate by creating an integrated component. The heat exchange plate is designed with structural ribs and reinforcement features that provide mechanical support to the battery pack, eliminating the need for separate structural elements like beams and crossmembers. This integration directly reduces weight while maintaining the required mechanical strength.
Solution Approach 2:
The heat exchange plate is designed to perform multiple functions simultaneously: thermal management (heat exchange) and structural support. By incorporating structural reinforcement features into the plate design, it serves as both a thermal management component and a structural element, replacing dedicated structural components and reducing overall system weight.
2Strength
If additional structural elements (beams, crossmembers, protectors) are added to ensure mechanical strength of the battery pack, then the mechanical strength and reliability are improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines the structural support function with the heat exchange plate, creating a single integrated component. This reduces the total number of parts that need to be manufactured, procured, and assembled, thereby lowering manufacturing costs despite maintaining the required mechanical strength through integrated reinforcement features.
Solution Approach 2:
The heat exchange plate is designed to perform multiple functions simultaneously: thermal management and structural support. This multi-functionality reduces the bill of materials and assembly complexity, leading to cost savings that offset the enhanced structural capabilities.
3Strength
If additional structural elements (beams, crossmembers, protectors) are added to ensure mechanical strength of the battery pack, then the mechanical strength and reliability are improved, but the CO2 emissions increase
Solution Approach 1:
The patent merges the structural support function with the heat exchange plate, eliminating the need for separate structural elements. This reduction in material usage directly decreases the CO2 emissions associated with manufacturing and transporting additional components, while the integrated design maintains the required mechanical strength.
Solution Approach 2:
The heat exchange plate performs dual functions as both a thermal management device and a structural support element. This multi-functionality reduces the overall material footprint and manufacturing emissions, achieving the required mechanical strength with lower environmental impact.
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
Reduces the number of structural components needed, saving costs, weight, and CO2 emissions while maintaining mechanical integrity and thermal management efficiency.
Implementation Method 1
Heat-transfer fluids can thus absorb heat emitted by the one or more batteries in order to cool them
Implementation Method 2
The heat exchange plates are generally made of metal and are made up of two metallic plates that are pressed and brazed against one another
Data Source
AI summary
The invention relates to a heat exchange plate for thermal management of a battery pack, having first and second plates, at least the first plate having at least one channel, the first and second plates adjoining one another such that the channel partially delimits at least one duct of a circuit for circulation of a heat-transfer fluid. The first plate is made of a first material and the second plate is made of a second material that is different from the first material and confers a structural function on the second plate.