Battery Pack Cooling Duct Assembly with Compressed Cell Contact
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Solution Overview
Problem
The manufacturing of electric vehicle battery systems faces challenges in ensuring reliable electrical connections and efficient cooling of battery cells, which are crucial for maintaining optimal temperature and extending battery life, while also reducing manufacturing costs and improving assembly efficiency.
Innovation Solution
A method involving the use of a cooling duct between battery cells, where forces are applied to press the cells against the duct for effective thermal contact, and busbars are connected to trays to facilitate electrical connections, allowing for efficient assembly and replacement of modular battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling duct is placed between battery cells to improve thermal management, then temperature control is improved, but manufacturing complexity increases
Solution Approach 1:
The battery system is divided into modular units with cooling ducts integrated between cell groups. Each cooling duct serves a specific segment of battery cells, allowing independent assembly and cooling zone management. This segmentation enables simplified manufacturing compared to a monolithic cooling system.
Solution Approach 2:
The cooling duct structure is merged with the battery cell assembly structure, where the duct serves dual purposes as both a thermal management component and a structural element that helps maintain cell spacing and alignment during assembly.
2Loss of energy
If forces are applied to press battery cells against cooling duct for thermal contact, then heat dissipation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The pressing mechanism is designed to apply dynamic, controlled forces during assembly that automatically ensure adequate thermal contact between cells and cooling duct. The force application is optimized to achieve necessary contact pressure without requiring ultra-precise positioning, accommodating normal manufacturing tolerances.
3Productivity
If modular battery packs with trays are used to improve assembly efficiency, then productivity increases, but device complexity increases
Solution Approach 1:
The battery system is divided into modular packs with trays that hold groups of cells. Each tray assembly can be manufactured and tested independently, then quickly assembled into the complete battery system. This modular segmentation dramatically improves assembly efficiency while the standardization of modules keeps overall system complexity manageable.
Solution Approach 2:
The tray structure serves multiple functions: mechanical support for battery cells, thermal management integration, electrical connection pathways, and structural alignment features. This multi-functionality reduces the number of separate components needed, offsetting the complexity introduced by modularity.
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
This approach enhances thermal management and electrical connectivity, improving the reliability and safety of battery systems while reducing manufacturing costs and increasing the distance an electric vehicle can travel on a single charge.
Implementation Method 1
The coolant system of electric vehicle can be physically extended to the battery system to remove excess heat
Implementation Method 2
An electric vehicle uses one or more electric motors powered by electrical energy stored in a rechargeable battery system
Data Source
AI summary
A method of manufacturing a battery pack for an electric vehicle is disclosed. The method includes placing a cooling duct between first and second pluralities of battery cells, and applying a first force to the first plurality of battery cells and a second force to the second plurality of batteries. The first and second forces cause the first and second pluralities of battery cells to press against the cooling duct, the first plurality of battery cells is pressed against a first side of the cooling duct, the second plurality of battery cells is pressed against a second side of the cooling duct, and the first side of the cooling duct is opposite the second side of the cooling duct. The method also includes placing the first and second plurality of battery cells in a first tray configured to hold the first and second plurality of battery cells.