Thermal Exchange Plate TIM Layout for Battery Pack Cooling
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Solution Overview
Problem
Existing traction battery packs face inefficiencies in thermal management due to the uniform distribution of thermal interface material (TIM) over thermal exchange plates, which does not align with the pattern of coolant channels, leading to suboptimal thermal energy transfer and increased material usage.
Innovation Solution
A thermal interface material is dispensed onto a thermal exchange plate in a pattern that mimics the distribution of coolant channels, ensuring optimal placement for thermal energy transfer between battery arrays and coolant channels, with open areas lacking TIM to reduce overall material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal interface material is uniformly distributed over the thermal exchange plate, then thermal energy transfer is maintained across the entire surface, but material usage is increased and thermal efficiency is suboptimal
Solution Approach 1:
The patent applies local quality by varying the distribution of thermal interface material according to the coolant channel pattern. TIM is concentrated in regions corresponding to coolant channels where thermal transfer is most needed, while open areas without TIM are placed in regions where thermal transfer requirements are lower. This non-uniform distribution optimizes thermal efficiency while reducing overall material usage.
2Quantity of substance
If thermal interface material is concentrated in specific areas matching coolant channels, then material usage is reduced, but thermal energy transfer efficiency may be compromised
Solution Approach 1:
The patent employs preliminary action by pre-positioning the thermal interface material in optimal locations before the battery array is installed. The TIM is dispensed in a pattern that mimics the coolant channel distribution, ensuring that thermal contact is optimized at the interface between the battery and thermal exchange plate before compression occurs during assembly.
3Loss of substance
If open areas without thermal interface material are created, then material cost and weight are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses copying by creating a TIM distribution pattern that replicates the coolant channel pattern on the thermal exchange plate. The dispensing system follows the coolant channel geometry, placing TIM in regions that mirror the channel locations. This copying approach simplifies the dispensing process while achieving optimal thermal contact where it is most needed.
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 efficiency while minimizing the amount of TIM required, resulting in cost and weight savings by strategically positioning TIM in high-transfer areas and omitting it from low-transfer areas.
Implementation Method 1
A thermal interface material may also be used to increase the thermal conductivity between the battery cells and the thermal exchange plate
Data Source
AI summary
A traction battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a thermal exchange plate having a plurality of coolant channels distributed within the thermal exchange plate according to a first pattern, and a thermal interface material disposed on a surface of the thermal exchange plate according to a second pattern. The first pattern mimics the second pattern.