Battery Module Cooling Chamber With Reinforcing Ribs for Leak-Safe Airflow
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Solution Overview
Problem
Existing cooling structures for battery packs face issues with insufficient rigidity, leading to potential leaks and uneven cooling due to deflection or distortion from vibrations, and increased manufacturing costs and complexity from multiple components and assembly steps.
Innovation Solution
A cooling structure that interposes a chamber between adjacent battery modules, using a box-shaped body with reinforcing ribs for enhanced rigidity and sealing, and a large cross-sectional air passage to ensure uniform cooling air distribution without the need for additional supporting components like fins and flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fins and flanges are integrally formed with the beam to create cooling passages, then cooling air can be supplied to battery stacks, but the structure has insufficient rigidity and may deflect or distort due to vibrations
Solution Approach 1:
The cooling structure is divided into separate components: the beam structure and the chamber structure. The chamber is positioned between battery stacks and communicates with the beam through openings, allowing cooling air flow while independent from the beam. This segmentation prevents vibration-induced distortion from affecting sealing performance.
Solution Approach 2:
The chamber acts as an intermediary structure between the beam and the battery stacks. It receives cooling air from the beam through openings and distributes it to the battery stacks, while its rigid box shape with reinforcing ribs provides structural stability independent of the beam's vibrations.
2Reliability
If multiple components like fins, flanges, and supporting structures are used to ensure cooling air flow, then cooling performance can be maintained, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The chamber integrates multiple functions into a single structure: it serves as the cooling air passage, provides structural support between battery stacks, and ensures sealing through its box shape with openings. This merging eliminates the need for separate fins, flanges, and supporting structures, reducing component count and assembly complexity.
Solution Approach 2:
The chamber structure performs multiple functions simultaneously: it guides cooling air from the beam to the battery stacks, provides mechanical support between adjacent battery stacks, and maintains sealing through its rigid box configuration. This multi-functionality reduces the overall system complexity.
3Manufacturing precision
If a box-shaped chamber with openings is used to distribute cooling air between battery modules, then uniform cooling can be achieved, but the structure may lack sufficient rigidity without additional support components
Solution Approach 1:
Reinforcing ribs are strategically added to specific locations on the chamber body where structural strength is needed, while maintaining the box shape with openings for cooling air flow. This localized reinforcement provides rigidity without obstructing the cooling air distribution paths.
Solution Approach 2:
The chamber is formed as a rigid box structure that combines the functionality of air distribution passages with structural support elements. The integrated design creates a composite structure that simultaneously achieves uniform cooling air distribution and sufficient structural rigidity.
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 improved rigidity and sealing, reducing the risk of cooling air leaks and ensuring uniform cooling, while minimizing the number of components and assembly steps, thus lowering manufacturing costs and pack mass.
Implementation Method 1
The cooling air is sent to the battery modules via the chamber
Data Source
AI summary
A cooling structure includes battery modules including battery cells, an intake duct allowing cooling air to flow to the battery modules, and a chamber communicating with the intake duct. The chamber is interposed between the adjacent battery modules. The chamber includes a body, sealing members, and a reinforcing rib. The body has a box shape and includes openings at both ends in an arrangement direction of the battery modules, and communicates with each battery module. Each sealing member is disposed at a coupling area. The reinforcing rib is provided in an internal space of the body and coupled to first and second parts of the body apart from each other in a height direction of the body. The reinforcing rib extends between the first and second parts. The body is supported with being held between the battery modules. The cooling air is sent to the battery modules via the chamber.