Integrated Battery Cooling Plate Design for Leakage Reduction
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Solution Overview
Problem
Existing battery cooling systems for hybrid and electric vehicles require complex configurations with many parts, leading to increased volume, weight, and the risk of refrigerant leakage, while also compromising structural rigidity and energy density.
Innovation Solution
A simplified battery system design featuring a channel plate with integrated cooling channels, a first end plate with inflow and outflow ports, a second end plate for structural rigidity, and a cover plate, which minimizes components and optimizes the cooling circuit to reduce refrigerant leakage and enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a water cooling system using refrigerant is used to cool the battery module, then cooling performance is improved, but the volume and weight of piping and connection devices increase
Solution Approach 1:
The patent merges the cooling channel with the end plates by integrating the refrigerant circulation path directly into the structural components (first end plate, second end plate, and channel plate). This eliminates the need for separate piping systems, thereby improving cooling performance while reducing the weight and volume of cooling components.
Solution Approach 2:
The end plates serve dual functions: they provide structural support for the battery module while simultaneously acting as cooling channels for refrigerant circulation. This multi-functionality reduces the number of separate components needed, decreasing overall system weight and volume while maintaining effective cooling.
2Temperature
If various piping and connection devices are used for refrigerant circulation, then cooling effectiveness is improved, but the number of parts and device complexity increase
Solution Approach 1:
The cooling channels are merged with the end plates and channel plate structures, eliminating the need for separate piping and connection devices. The refrigerant flows directly through the integrated channels formed by these structural components, simplifying the system while maintaining cooling effectiveness.
Solution Approach 2:
The patent extracts the cooling function from separate piping components and integrates it directly into the end plates and channel plate. This extraction and integration approach eliminates unnecessary intermediate components, reducing part count and simplifying the overall system architecture.
3Temperature
If multiple separate cooling components are used, then cooling coverage is improved, but the leakage risk of refrigerant increases
Solution Approach 1:
By merging the cooling channels with the end plates and channel plate, the patent creates an integrated cooling system with fewer connection points and joints. This integration reduces the number of potential leakage points while maintaining comprehensive cooling coverage across the battery module.
Solution Approach 2:
The patent removes separate piping components that would create multiple connection interfaces and potential leakage points. The refrigerant circulation path is extracted from external piping and embedded within the integrated plate structures, minimizing exposure and leakage risk.
4Strength
If unnecessary space is not minimized, then structural rigidity is maintained, but energy density decreases
Solution Approach 1:
The end plates and channel plate serve multiple functions simultaneously: they provide structural rigidity to support the battery module while also serving as cooling channels for refrigerant circulation. This multi-functionality eliminates unnecessary separate components and space, increasing energy density without compromising structural strength.
Solution Approach 2:
The structural support function and cooling function are merged into the same components (end plates and channel plate). This integration eliminates the need for separate structural frames and cooling pipes, optimizing space utilization and increasing energy density while maintaining required 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 stable and efficient heat dissipation for battery modules with reduced component count, ensuring structural rigidity and increased energy density by minimizing unnecessary space and simplifying the cooling circuit, thereby reducing refrigerant leakage.
Implementation Method 1
a channel plate of which one side surface is contacted with a battery module and including a cooling channel therein in which refrigerant circulates to cool the battery module
Data Source
AI summary
A battery system is provided. The system includes a channel plate of which one side surface is contacted with a battery module and includes a cooling channel therein in which refrigerant circulates to cool the battery module. A first end plate supplies the refrigerant transmitted from the outside through an inflow port to the channel plate and transmits the refrigerant passing through the channel plate to the outside through an outflow port and is coupled to the channel plate to form a space surrounding the battery module. A second end plate is coupled to the channel plate opposite the first end plate to form the space surrounding the battery module. A cover plate is coupled to the first end plate and the second end plate opposite the channel plate to form the space surrounding the battery module.