Vacuum-Insulated Battery Pack Barriers With Integrated Heat Exchange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing traction battery packs face challenges in efficiently managing temperature fluctuations and ambient thermal interference, which affect battery performance and life.
Innovation Solution
Incorporation of a thermal barrier structure with a heat exchanger portion for temperature management and a vacuum portion for insulation, featuring an internal cooling circuit and evacuated sealed cavity to isolate battery cells from external conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management systems are used, then temperature control is achieved, but the system occupies excessive space and adds significant weight
Solution Approach 1:
The patent combines the thermal barrier structure with the battery cell holder assembly into a single integrated unit. The thermal barrier walls are formed as integral parts of the holder structure, eliminating the need for separate thermal management components and reducing overall system volume while maintaining temperature control functionality.
Solution Approach 2:
The patent implements nested thermal barrier walls within the battery cell holder assembly. Multiple thermal barrier walls are positioned between battery cells and the holder walls, creating layered insulation structures that maximize thermal protection within limited space, effectively nesting insulation layers within the structural framework.
2Temperature
If traditional thermal management systems are used, then temperature control is achieved, but the system weight increases significantly
Solution Approach 1:
The thermal barrier structure is merged with the battery cell holder assembly, eliminating redundant structural components. The holder walls serve dual purposes as both structural support and thermal barrier, reducing material usage and overall system weight while maintaining temperature control capabilities.
Solution Approach 2:
The patent applies thermal barrier walls selectively at specific locations where thermal management is most critical, rather than using uniform insulation throughout the entire structure. This localized approach reduces material weight while effectively controlling temperature at key battery cell interfaces.
3Reliability
If ambient thermal interference is reduced, then battery performance is improved, but the structural complexity increases
Solution Approach 1:
The thermal barrier structure is integrated into the battery cell holder assembly, combining structural support and thermal protection functions into a single component system. This integration reduces the number of separate parts and assembly steps, thereby simplifying the overall device complexity while maintaining effective thermal isolation for improved battery performance.
4Object-affected harmful factors
If thermal isolation is enhanced, then noise from external environment is decreased, but the manufacturing complexity increases
Solution Approach 1:
The thermal barrier walls are formed as integral parts of the battery cell holder assembly, eliminating the need for separate manufacturing and assembly steps for thermal insulation components. This integration simplifies the manufacturing process while maintaining effective thermal and noise isolation from the external environment.
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
Enhances battery performance and life by stabilizing temperatures, reducing thermal transfer, and decreasing noise while maintaining packaging efficiency.
Implementation Method 1
a vacuum portion (40) that establishes a sealed cavity (58) of the thermal barrier structure. In an embodiment, the sealed cavity is evacuated of air
Implementation Method 2
a heat exchanger portion (38) that establishes an internal cooling circuit (48) of the thermal barrier structure
Implementation Method 3
a vacuum portion (40) that establishes a sealed cavity (58) of the thermal barrier structure
Data Source
AI summary
Exemplary traction battery pack designs are described for use in electrified vehicles. An exemplary traction battery pack may include one or more thermal barrier structures. In some implementations, each thermal barrier structure may include both a heat exchanger portion for stabilizing a temperature of battery cells of the traction battery pack and a vacuum portion for isolating the battery cells and/or the heat exchanger portion from ambient conditions. In other implementations, the thermal barrier structure may include only the vacuum portion. The thermal barrier structure may be arranged to interface with a battery array of the traction battery pack and could be integrated as part of an enclosure assembly of the traction battery pack.