Battery Box Beam Layout for Stable Module Heat Exchange
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Solution Overview
Problem
The existing battery box designs suffer from heat transfer issues between the heat exchange plate and the bottom planes of internal beams, which affects the heat exchange efficiency and stability of the battery's operating temperature.
Innovation Solution
A battery box design where the bottom plane of internal beams is partly in contact with the top plane of the heat exchange plate, with heat insulation glue filled between them, and a fastener extending into an accommodating cavity to reduce contact area and heat exchange, along with features like recessed planes and bulges to minimize heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the heat exchange plate is fixed to the beams of the lower frame body, then the structural stability is improved, but heat transfer between the heat exchange plate and beams occurs, affecting heat exchange efficiency
Solution Approach 1:
The bottom plane of the internal beam is divided into multiple regions: a first contact plane that contacts the heat exchange plate, and second/third recessed planes that are spaced apart from the heat exchange plate. This segmentation reduces the contact area between the beam and heat exchange plate, minimizing parasitic heat transfer while maintaining structural stability through the fastener connection at the contact plane.
Solution Approach 2:
Heat insulation glue is introduced as an intermediary material filled in the gaps between the recessed planes of the internal beam and the heat exchange plate. This intermediary provides thermal insulation to prevent heat transfer through the air gap, while the fastener serves as a mechanical intermediary to maintain the spacing structure. The combination effectively isolates thermally while maintaining structural integrity.
2Loss of energy
If the bottom plane of internal beam is partly in contact with heat exchange plate, then heat transfer is reduced, but structural support may be compromised
Solution Approach 1:
The bottom plane is segmented into a contact portion (first plane) and non-contact portions (second and third recessed planes). The contact portion provides localized structural support where needed, while the recessed portions reduce heat transfer area. This selective contact approach maintains sufficient structural support while achieving heat transfer reduction.
Solution Approach 2:
The internal beam bottom plane features asymmetric geometry with specific regions recessed and others in contact. The fastener is positioned asymmetrically to provide mechanical support at the contact plane. This asymmetric design allows optimization of both thermal performance (by reducing contact area in specific regions) and structural support (by maintaining contact and fastener connection at critical locations).
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 reduces heat exchange between the heat exchange plate and internal beams, enhancing the stability, constancy, and controllability of the battery's operating temperature by minimizing contact area and using heat insulation to prevent heat transfer.
Implementation Method 1
heat insulation glue, which is filled between the third plane and the top plane of the heat exchange plate
Data Source
Figure 1
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AI summary
This application provides a battery box, which includes: a heat exchange plate; a lower frame body located on the heat exchange plate, where the lower frame body includes edge beams and internal beams, the edge beams form a circumferential closure opened in an up-down direction, the edge beams and the heat exchange plate together form an accommodating space with an upward opening, and the internal beams are located inside the accommodating space and divide the accommodating space into sub-accommodating spaces for placing battery modules; the heat exchange plate is used to support the battery modules and exchanges heat with batteries of the battery modules, and a bottom plane of an internal beam is partly in contact with a top plane of the heat exchange plate in the up-down direction. By making the bottom plane of the internal beam partly in contact with the top plane of the heat exchange plate in the up-down direction, the contact area between the bottom plane of the internal beam and the top plane of the heat exchange plate is reduced. This reduces the heat exchange between the heat exchange plate and the bottom plane of the internal beam, and in turn the impact on the heat exchange between the heat exchange plate and the battery modules (mainly the batteries) is reduced, and the stability, constancy and controllability of the operating temperature of the batteries are improved.