Battery Case Frame and Tub Insert for Impact and Thermal Control
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Solution Overview
Problem
Existing battery pack systems for electric vehicles face challenges in protecting battery modules from external influences such as humidity, static and dynamic loads, impact, and temperature variations while maintaining thermal efficiency and structural integrity, which affects vehicle safety and energy economy.
Innovation Solution
A battery case with a frame-like support structure and tub-shaped insert that hermetically seals battery modules, absorbs impact energy, and integrates cooling/heating means, made from materials like metal beams and fiber-reinforced composites, to efficiently transfer and manage loads and thermal energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery packs are mounted under the vehicle floor, then vehicle stability and driving characteristics are improved, but protection from external influences (humidity, impact, ground contact) becomes more difficult
Solution Approach 1:
The battery pack is divided into modular units that can be independently protected and mounted. Each battery module is enclosed in its own protective housing, allowing the system to maintain stability while protecting individual components from environmental hazards.
Solution Approach 2:
Protective enclosures and sealing elements are introduced as intermediary components between the battery pack and the harsh under-floor environment. These intermediaries shield the batteries from humidity, impact, and ground contact while allowing the pack to remain mounted in the optimal low-position location.
2Reliability
If heavy protective structures are added to shield battery modules from impact and external influences, then reliability is improved, but vehicle weight increases
Solution Approach 1:
The protective structure utilizes composite materials that provide high strength and impact resistance with reduced weight compared to traditional metal structures. This allows the battery pack to achieve the required protection level while minimizing the additional weight added to the vehicle.
Solution Approach 2:
Flexible protective shells and thin-film sealing layers are employed to provide impact absorption and environmental protection without the weight penalty of rigid heavy-duty enclosures. These flexible elements can deform to absorb impact energy while maintaining protection.
3Object-affected harmful factors
If complex protective systems with multiple components are implemented, then protection effectiveness is improved, but device complexity and assembly time increase
Solution Approach 1:
Multiple protective functions (impact protection, sealing, thermal management, structural support) are merged into integrated components rather than using separate elements for each function. This reduces the total number of parts while maintaining comprehensive protection effectiveness.
Solution Approach 2:
Protective components are designed to perform multiple functions simultaneously. For example, the protective enclosure serves as both impact shielding, environmental sealing, and structural support, eliminating the need for separate dedicated components for each function.
4Temperature
If adequate thermal management systems are integrated into the battery case, then temperature control is improved, but device complexity increases
Solution Approach 1:
Thermal management functionality is merged with the structural components of the battery case. The protective enclosure incorporates thermal management channels and heat dissipation features directly into its structure, eliminating the need for separate thermal management systems.
Solution Approach 2:
The battery case structure serves dual purposes: providing mechanical protection and enabling thermal management. The same components that protect against impact also facilitate heat transfer and temperature control, reducing overall system complexity.
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
The solution provides effective protection and thermal management for battery packs, enhancing safety, reducing weight, and improving energy efficiency by allowing efficient cooling and heating, while minimizing complexity and assembly time.
Implementation Method 1
at least one cooling means (13) which in an assembled position is in thermal contact with the at least one battery module (3) arranged in the tub-shaped insert (7)
Implementation Method 2
An energy absorption layer is formed between the top layer and the bottom layer... The energy absorption layer is made of resilient material
Data Source
AI summary
The invention is directed to a battery case (1) comprising a compartment (2) for at least one battery module (3). Two first outer beams (4) extending in a first spatial direction (x) and two second outer beams (5) extending in a second spatial direction (y) are arranged essentially perpendicular to the first spatial direction. The first and second beams (4, 5) are forming a frame-like support structure (6). A tub-shaped insert (7) is connected to the grid like support structure (6) from a third direction (z) arranged essentially perpendicular to the first and the second direction (x, y). A closure (8) closes the tub-shaped insert (7) to form the closed compartment (2) for the at least one battery module.