Integrally Cast Battery Case with Heat Exchange Member

Solution Overview

Problem

Existing battery pack designs face challenges in efficiently managing heat generation during high-power and long-duration operations, leading to increased manufacturing costs and assembly complexities due to separate components and bolt-fastening processes.

Innovation Solution

A case for a battery pack with a heat exchange member integrally formed with the case member, where the heat exchange member is welded through brazing and manufactured via die-casting, eliminating the need for additional covers and reducing assembly tolerances, thereby enhancing reliability and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If separate heat exchange member and case member are used with bolt-fastening process, then heat exchange function is achieved, but manufacturing time and costs increase

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidmanufacturing time

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The heat exchange member and case member are merged into a single integrally formed component through die-casting. This eliminates the need for separate manufacturing and assembly processes, reducing manufacturing time and costs while maintaining the heat exchange functionality through the integrated structure with incorporated flow paths.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If separate heat exchange member and case member are used with bolt-fastening process, then heat exchange function is achieved, but manufacturing costs increase

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat exchange member and case member are merged into a single integrally formed component through die-casting. This eliminates the need for separate manufacturing and assembly processes, reducing manufacturing time and costs while maintaining the heat exchange functionality through the integrated structure with incorporated flow paths.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If separate heat exchange member and case member are used with bolt-fastening process, then assembly is achieved, but assembly complexities increase

Engineering Contradiction:

Improveassembly easeVSAvoidassembly complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The heat exchange member and case member are merged into a single integrally formed component through die-casting. This eliminates the need for separate manufacturing and assembly processes, reducing manufacturing time and costs while maintaining the heat exchange functionality through the integrated structure with incorporated flow paths.

Inventive Principle:

Principle #5Merging (Combining)

4Temperature

If separate heat exchange member and case member are used, then heat exchange function is achieved, but assembly tolerances increase

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidassembly tolerance

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The heat exchange member and case member are merged into a single integrally formed component through die-casting. This eliminates the need for separate manufacturing and assembly processes, reducing manufacturing time and costs while maintaining the heat exchange functionality through the integrated structure with incorporated flow paths.

Inventive Principle:

Principle #5Merging (Combining)

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 solution reduces manufacturing time and costs, improves product accuracy, and increases the contact area for better heat management and stability, allowing for efficient heat dissipation in high-power battery packs.

Implementation Method 1

a heat exchange member on any one surface of the case member... An upper surface of the heat exchange member may include a flow path through which a cooling medium moves

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heat exchange member may be welded to the case member through brazing

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS10205144B2Case for battery pack

Publication Date: 2019.02.12 SAMSUNG SDI CO LTD

AI summary

A case for a battery pack includes a case member configured to accommodate a plurality of battery cells therein and a heat exchange member on any one surface of the case member, the heat exchange member being integrally formed with the case member.