Traction Battery Thermal Plate with Counter-Flow Channels

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current thermal management systems for high voltage batteries in vehicles face inefficiencies in heat transfer and temperature uniformity, leading to variations in battery cell temperatures that can affect vehicle performance and battery life.

Innovation Solution

A thermal plate design with specific channel configurations and flow features, including inlet and outlet ports, outer and inner channels, and surface enhancements like dimples or metal foam, that promote counter-directional fluid flow and increased surface area for effective heat transfer across the battery cell array.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional thermal management systems are used, then cooling function is provided, but heat transfer efficiency is insufficient and temperature uniformity is poor

Engineering Contradiction:

Improvetemperature uniformityVSAvoidheat transfer efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The thermal plate is segmented into multiple channels (first channel, second channel, third channel, fourth channel) with alternating flow directions. This segmentation allows different regions of the battery pack to receive cooling fluid at different temperatures, improving both heat transfer efficiency and temperature uniformity across the battery cells.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different channels are assigned different flow directions (alternating first/second direction in adjacent channels) to create local quality variations. This ensures that heat is extracted more efficiently from different regions of the battery pack, addressing local thermal hotspots and improving overall temperature uniformity.

Inventive Principle:

Principle #3Local quality

2Loss of energy

If simple channel configuration is used, then device complexity is low, but heat transfer efficiency is insufficient

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidchannel configuration complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The cooling system is divided into multiple segmented channels with defined flow paths. Each channel is configured to serve specific regions of the battery pack, improving heat transfer efficiency through systematic fluid distribution while maintaining a manageable structural complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple channels are merged into a single thermal plate structure, integrating several cooling functions into one component. This combines the complexity of multiple channels with the simplicity of a single plate design, achieving efficient heat transfer without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If adjacent channels have same flow direction, then fluid flow control is simple, but temperature uniformity deteriorates

Engineering Contradiction:

Improvetemperature uniformityVSAvoidfluid flow control

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Adjacent channels are assigned alternating flow directions (first direction, second direction) to create local quality differences. This alternating pattern ensures that cooling fluid flows in opposite directions in adjacent channels, improving temperature uniformity by preventing thermal stratification and hotspots.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of having all channels flow in the same direction, the system inverts the flow direction in alternating channels. This inversion strategy creates counter-flow patterns that enhance heat transfer efficiency and improve temperature uniformity across the battery pack.

Inventive Principle:

Principle #13The other way round (Inversion)

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 enhances heat transfer efficiency and maintains a more uniform temperature distribution across the battery cells, improving vehicle performance and prolonging battery life by minimizing temperature variations.

Implementation Method 1

heat from the array travels from a top portion of the thermal plate, through the walls, and to a bottom portion of the thermal plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

fluid traveling through any two adjacent channels flows in opposite directions

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

At least some of the surfaces of the thermal plate defining the channels may include flow features configured to increase an effective surface area of the at least some of the surfaces. The flow features may include dimples, pedestals, or metal foam.

Methodology Applied

Scientific EffectSurface area enhancement:

Data Source

PatentUS9452683B2Traction battery thermal plate with longitudinal channel configuration

Publication Date: 2016.09.27 FORD GLOBAL TECH LLC

AI summary

A traction battery assembly for a vehicle is provided. The traction battery assembly may include a battery cell array and a thermal plate configured to support the battery cell array. The thermal plate may define an inlet port, two outer channels each having a channel inlet in communication with the inlet port, at least three inner channels disposed between the outer channels, and an outlet port. The ports and channels may be arranged such that fluid traveling through any two adjacent channels flows in opposite directions and fluid, when exiting the thermal plate, empties from one or more of the inner channels into the outlet port without first entering the channel inlets.