Vehicle Battery Pack Cooling Layout for Strength and Weight
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Solution Overview
Problem
Existing battery systems for vehicles face challenges in securing structural robustness while minimizing weight and enhancing cooling performance, particularly due to the reduction in the number of through-mountings and the structural limitations of cooling blocks constructed by fixing upper and lower plates with a press.
Innovation Solution
The proposed battery system incorporates a cooling block positioned under the battery pack and an improved cooling passage configuration that connects passages in the cooling block to those in side and longitudinal members, allowing coolant to flow independently through separate paths, thereby enhancing cooling efficiency and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the number of through-mountings and members is reduced to minimize weight, then weight is reduced, but structural robustness becomes insufficient
Solution Approach 1:
The cooling block is merged with the lower case to form an integrated structure, eliminating the need for separate cooling block components and reducing the number of through-mountings required. The longitudinal member is designed to serve both structural support and cooling passage functions simultaneously, reducing overall component count while maintaining strength.
Solution Approach 2:
The longitudinal member is designed to perform multiple functions: providing structural support for the battery modules, serving as a mounting structure, and containing cooling passages. This multi-functionality reduces the need for separate components, minimizing weight while maintaining structural robustness.
2Ease of manufacture
If cooling block is constructed by fixing upper and lower plates with a press, then manufacturing is simplified, but structural robustness is compromised
Solution Approach 1:
The cooling block is segmented into an integrated lower case structure rather than being constructed from separate upper and lower plates. This segmentation approach allows the cooling block to be formed as a single piece with the lower case, eliminating press-fixing requirements while maintaining structural integrity.
3Temperature
If cooling passage configuration is improved to enhance cooling performance, then cooling efficiency increases, but device complexity increases
Solution Approach 1:
The cooling passages are merged with the longitudinal member structure, allowing coolant to flow through the longitudinal member itself rather than requiring separate cooling channels. This integration simplifies the overall cooling system design while maintaining effective cooling performance through optimized coolant flow paths.
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 configuration effectively improves cooling performance by shortening the coolant's cooling path and optimizing the cooling path, while also securing structural robustness by distributing the load effectively through the connection of the longitudinal member and cooling blocks.
Implementation Method 1
a cooling passage that forms a path through which coolant flows by connecting a passage in the cooling block to passages in members disposed on the left and right sides of the battery pack and a passage in a member disposed in the middle of the battery pack
Data Source
AI summary
An embodiment battery system includes a cooling block disposed under a battery pack and a cooling passage that defines a path through which coolant flows by connecting a first passage in the cooling block to second passages in first members disposed on left and right sides of the battery pack and a third passage in a second member disposed at a middle of the battery pack.