Integrated Battery Cooling Block Structure for Leak Prevention
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Solution Overview
Problem
Existing battery cooling systems face safety risks due to leakage of cooling water at connections between cooling blocks, which can lead to short circuits and fires, especially under external shocks or vibrations.
Innovation Solution
A battery module cooling structure with cooling blocks featuring an upper panel, a lower panel, and a side wall that extends along the periphery, where the side wall is welded to the upper panel, forming an accommodation part for cooling water flow, and a flange part that interconnects adjacent cooling blocks with inlet and outlet holes, reducing the risk of water leakage and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling blocks are connected through pipelines with multiple connection portions, then cooling water can flow between cooling blocks, but leakage risk increases under external shocks or vibrations
Solution Approach 1:
The patent merges the connection function into the cooling block structure itself by integrating connection portions directly onto the cooling blocks. This eliminates separate pipelines and reduces the number of connection points, thereby reducing leakage risk while maintaining cooling functionality. The cooling blocks are directly coupled to each other through these integrated connection portions, simplifying the overall structure.
Solution Approach 2:
The cooling block is divided into an upper cooling block and a lower cooling block with distinct functions. The upper cooling block includes connection portions for coupling to adjacent cooling blocks, while the lower cooling block includes the cooling passage. This segmentation allows for specialized design of each portion, optimizing both cooling performance and connection reliability.
2Reliability
If multiple connection portions are used to connect cooling blocks, then cooling water distribution is improved, but the number of potential leakage points increases
Solution Approach 1:
The connection portions are merged into the cooling block structure itself rather than being separate pipeline components. This integration reduces the number of discrete connection points that could leak, while still achieving proper cooling water distribution through the integrated connection design.
3Ease of manufacture
If traditional pipeline connections are used between cooling blocks, then cooling water flow is achieved, but assembly complexity and part count increase
Solution Approach 1:
The patent combines the cooling block structure with the connection structure into a single integrated component. The connection portions are formed as integral parts of the cooling blocks themselves, eliminating the need for separate pipeline components and reducing assembly complexity while maintaining cooling water flow functionality.
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 effectively prevents cooling water leakage, reducing the risk of short circuits and fires, while also simplifying assembly processes and reducing the number of parts, ensuring safer and more efficient cooling of battery modules.
Implementation Method 1
the side wall is welded to the upper panel
Implementation Method 2
absorbs heat generated in the battery in each cooling block
Implementation Method 3
cooling water flows, and in which cooling water flows
Data Source
AI summary
A battery module cooling structure includes a plurality of battery modules, a plurality of cooling blocks arranged adjacent to the battery modules to cool the battery modules, and a cooling passage which passes through the cooling blocks adjacent to each other and in which cooling water flows. Each of the cooling blocks includes an upper panel that closes an upper portion of the cooling block and forms an upper body, a lower panel that is spaced apart from the upper panel and closes a lower portion of the cooling block, and a side wall that extends along a periphery of the lower panel and has an end fixed to the upper panel.