Integrated Battery Chiller Structure for Vehicle Frame Cooling
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Solution Overview
Problem
Current battery chiller designs for vehicles are limited by the brazing process and shape/size constraints of stamped aluminum plates, which restricts their effectiveness and manufacturing flexibility.
Innovation Solution
The battery chiller is additively manufactured within a structural support member, featuring spaced apart coolant and refrigerant chambers connected by hollow pins for enhanced fluid communication, allowing for more complex geometries and integration with vehicle frames, such as cross-members, for improved heat transfer and packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional brazing and stamped aluminum plate designs are used, then manufacturing process is simple, but design flexibility and heat transfer efficiency are limited
Solution Approach 1:
The patent combines the battery chiller with the vehicle frame structural member into a single integrated component. The chiller is additively manufactured as part of the frame structure, eliminating the need for separate manufacturing and assembly processes while enabling complex geometries that would be impossible with traditional stamped plates
Solution Approach 2:
The patent transitions from traditional brazing and stamping processes to additive manufacturing technology. This parameter change in the manufacturing process enables complex internal geometries, optimized heat transfer paths, and integration with the frame structure that were previously unachievable
2Power
If stamped aluminum plates with dimples are used, then manufacturing is straightforward, but heat transfer efficiency and fluid communication are insufficient
Solution Approach 1:
The patent employs hollow pins distributed throughout the chiller structure that create fluid communication pathways between adjacent coolant chambers. This porous-like structure enables efficient heat transfer while maintaining structural integrity, achieving high heat transfer efficiency without requiring complex stamped plate geometries
Solution Approach 2:
The patent transitions from two-dimensional stamped plate designs to three-dimensional additively manufactured structures with internal hollow pins. This dimensional change enables fluid communication pathways that extend through the thickness of the structure, significantly improving heat transfer efficiency
3Weight of stationary object
If battery chiller is manufactured separately, then assembly is simple, but packaging efficiency and weight are suboptimal
Solution Approach 1:
The battery chiller is merged with the vehicle frame structural member into a single integrated component. This integration eliminates the weight of separate components and fasteners, while the additive manufacturing process creates an optimized structure that reduces material usage compared to traditional separate component designs
Solution Approach 2:
The integrated frame-chiller component serves multiple functions simultaneously: it provides structural support for the vehicle frame, acts as a heat sink for battery cooling, and creates fluid communication pathways for coolant flow. This multi-functionality reduces overall system weight by eliminating redundant components
4Reliability
If traditional brazed construction is used, then structural integrity is adequate, but durability and space utilization are limited
Solution Approach 1:
The chiller is integrated within the frame structural member, utilizing the existing structural volume for dual purposes. This integration improves durability by eliminating brazed joints that are potential failure points, while maximizing space utilization by placing the chiller where it does not encroach on battery or other component space
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 enables a more efficient and flexible battery chiller design that enhances heat transfer, reduces weight, and increases durability while utilizing available space within vehicle structures, thereby improving vehicle performance and packaging efficiency.
Implementation Method 1
a plurality of hollow pins extending between the pair of spaced apart coolant chambers such that the pair of spaced apart coolant chambers are in fluid communication with each other via the plurality of hollow pins
Implementation Method 2
one chamber formed by a pair of adjacent stamped plates has cooling fluid that circulates and withdraws heat from the batteries
Implementation Method 3
an adjacent chamber formed by a pair of adjacent stamped plates has refrigerant that withdraws heat from the cooling fluid
Data Source
AI summary
A structural support member for a vehicle includes a structural member, a battery chiller additively manufactured and disposed at least partially within the support member. The battery chiller includes a pair of spaced apart coolant chambers and a plurality of hollow pins extending between the pair of spaced apart coolant chambers such that the pair of spaced apart coolant chambers are in fluid communication with each other via the plurality of hollow pins. A refrigerant chamber can be included and be between the pair of spaced apart coolant chambers such that coolant fluid flows from one of the pair of spaced apart coolant chambers to another of the pair of spaced apart coolant chambers through the refrigerant chamber via the plurality of hollow pins.