Battery Pack Assembly With Coolant Channels for Dense Cell Cooling
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Solution Overview
Problem
Existing battery assemblies face challenges in effectively cooling large-capacity secondary batteries due to heat accumulation, which can lead to deterioration and increased risk of explosion, and require improved fixing and impact resistance to enhance safety and efficiency.
Innovation Solution
A battery assembly design featuring a fixed frame that houses a battery cell stack, an outer frame with coolant circulation, and insulating plates and cooling spacers to enhance cooling efficiency and fixing force, along with busbar frame assemblies for electrical connection and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to increase output, then high output is achieved, but heat dissipation becomes difficult and temperature rises excessively
Solution Approach 1:
The battery pack is divided into multiple battery assemblies, each with its own cooling channel system. This segmentation allows heat to be dissipated locally at each assembly level, preventing heat accumulation in the entire pack while maintaining high output through the large number of stacked cells.
Solution Approach 2:
A cooling plate with cooling channels is introduced as an intermediary component between the battery cells and the heat sink. This mediator facilitates efficient heat transfer from the battery cells to the coolant flowing through the channels, enabling effective heat dissipation while maintaining the high-density cell configuration.
2Stability of the object's composition
If internal beams are added to partition battery assemblies, then structural stability is improved, but energy density decreases
Solution Approach 1:
The cooling plate serves multiple functions simultaneously: it provides structural support replacing traditional internal beams, creates cooling channels for heat dissipation, and maintains the positioning of battery assemblies. This multi-functionality eliminates the need for separate partition beams, thereby maintaining energy density while ensuring structural stability.
Solution Approach 2:
The structural support function and cooling function are merged into a single cooling plate component. By combining these functions, the design eliminates redundant structural elements like internal beams, maximizing the space available for battery cells and maintaining high energy density while providing both stability and thermal management.
3Productivity
If battery assemblies are concentratedly disposed to increase mileage, then vehicle mileage is extended, but heat accumulation increases and safety risks rise
Solution Approach 1:
The battery pack is segmented into multiple independent battery assemblies, each with its own cooling channels. This segmentation allows heat to be dissipated locally at each assembly, preventing heat propagation between assemblies and enabling concentrated disposal of multiple assemblies to extend mileage while maintaining safety.
Solution Approach 2:
The heat dissipation function is extracted and given dedicated cooling channels within each battery assembly. By removing heat accumulation as a constraint through this extraction, the design enables concentrated disposal of battery assemblies to extend vehicle mileage without compromising safety.
4Temperature
If conventional cooling methods are used, then cooling is provided, but cooling efficiency is insufficient for large-capacity batteries
Solution Approach 1:
The cooling system transitions from conventional surface cooling to three-dimensional cooling with channels penetrating through the cooling plate. This dimensional change allows coolant to flow through and around multiple battery cells simultaneously, dramatically increasing the cooling surface area and efficiency for large-capacity batteries.
Solution Approach 2:
A liquid coolant circulation system is implemented with inlet and outlet channels forming a closed loop. This hydraulic cooling system provides continuous forced convection cooling, significantly enhancing cooling efficiency compared to passive or air-based cooling methods, and is specifically designed to handle the thermal load of large-capacity batteries.
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 design improves energy density and cooling efficiency, ensuring safety by evenly distributing coolant flow and enhancing the assembly's mechanical stability and impact resistance.
Implementation Method 1
a inlet 160 and an outlet 170 for circulating a coolant into the outer frame 140
Implementation Method 2
a inlet 160 and an outlet 170 for circulating a coolant into the outer frame 140
Data Source
Figure 1
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AI summary
A battery assembly according to certain aspects of the present disclosure comprises: a battery cell stack in which a plurality of battery cells are stacked; a fixed frame that covers at least a part of the battery cell stack; an outer frame in which the battery cell stack and the fixed frame are housed; and an inlet and an outlet that circulates a coolant into the outer frame.