Vehicle Battery Case with Parallel Cooling and Extruded Rigidity
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Solution Overview
Problem
Existing battery cases for vehicles inefficiently cool batteries, particularly those at the rear, and result in unnecessary weight increase due to non-cooling channels being cooled, and compromised structural rigidity leading to reduced energy density.
Innovation Solution
A battery case with parallel cooling flow paths and extruded components for improved structural rigidity, utilizing sealers to prevent cooling medium flow into non-cooling channels, thereby enhancing cooling efficiency and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If series cooling flow paths are used in a general battery case, then the front battery is effectively cooled, but the rear battery cannot be effectively cooled
Solution Approach 1:
The cooling flow paths are segmented into multiple independent parallel channels instead of a single series path. Each channel is equipped with its own pump and control system, allowing simultaneous cooling of different battery regions (front and rear) with independently controlled cooling parameters, thereby achieving effective cooling across all battery positions.
2Strength
If flow paths are provided in portions that do not exchange heat with the battery, then the case structure is complete, but the weight of the battery case increases unnecessarily
Solution Approach 1:
The unnecessary flow paths that do not exchange heat with the battery are extracted and removed from the case structure. The cooling system is redesigned to include only the flow paths that are thermally coupled with battery components, eliminating dead weight while maintaining structural integrity through optimized support structures.
3Shape
If the case is manufactured by pressing without extrusion, then the case shape is advantageously implemented, but the structural rigidity is weaker requiring additional case members and penetration mounts
Solution Approach 1:
The case structure transitions from pressed homogeneous material to extruded composite construction. The extrusion process enables integration of reinforcing elements and optimization of material distribution within the case walls, achieving superior structural rigidity while maintaining shape flexibility. The extruded profile can incorporate varying wall thicknesses and embedded reinforcement features that pressed construction cannot achieve.
4Strength
If additional case members and penetration mounts are added to compensate for insufficient structural rigidity, then the structural rigidity is improved, but the weight increases and energy density decreases
Solution Approach 1:
The case structure merges the structural reinforcement function directly into the case body through extrusion, eliminating the need for separate case members and penetration mounts. The extruded case profile integrates support ribs, strengthening elements, and mounting features as inherent parts of the case structure, achieving the required rigidity without adding discrete components that would increase weight and reduce energy density.
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 ensures effective cooling of batteries regardless of their position, reduces unnecessary weight by preventing cooling medium flow in non-cooling channels, and increases energy density by allowing more cells to be installed.
Implementation Method 1
a cooling block configured to cool a battery
Implementation Method 2
configure a cooling block and a side member of a battery case as extruded components to ensure better structural rigidity
Data Source
AI summary
In a battery case for a vehicle of the present disclosure, channels of a battery cooling block are arranged in parallel, thereby efficiently cooling a battery regardless of a position of the battery. In addition, a sealer is used to prevent a cooling medium, which is introduced into a cooling channel that exchanges heat with the battery, from being introduced into a non-cooling channel that does not exchange heat with the battery, such that the cooling medium is not introduced into the battery case, which prevents an unnecessary in weight of the battery case. In addition, a cooling block and a side member of a battery case are configured as extruded components to ensure better structural rigidity than a general battery case made by pressing, thereby allowing more cells to be installed by reducing the number of case members and penetration mounts required to ensure structural rigidity of the battery case.