Non-conductive Battery Frame with Integrated Cooling Channels
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Solution Overview
Problem
Maintaining uniform operating temperatures across lithium ion cells within a battery pack is challenging due to manufacturing differences and varying thermal paths, affecting cell lifespan and performance.
Innovation Solution
A modular battery pack design featuring a non-conductive plastic frame with integrated cooling channels and isolation plates to manage temperature variations, including a snap fitting system for assembly efficiency and a compressive belt for cell restraint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery pack assembly methods are used, then assembly can be performed with simple components, but assembly time is excessive and the process is overly complicated
Solution Approach 1:
The patent combines multiple functions into the frame member: structural support, cooling channel integration, and assembly aid features (protrusions/recesses) are merged into a single component. This reduces the number of separate parts and simplifies the assembly process while maintaining productivity benefits.
Solution Approach 2:
The frame member is pre-formed with integrated cooling channels and assembly aid protrusions/recesses during manufacturing. This preliminary preparation eliminates the need for complex on-site assembly operations, reducing both assembly time and process complexity.
2Volume of stationary object
If cells are placed closely together to maximize battery pack density, then space utilization improves, but temperature variations between cells increase
Solution Approach 1:
The cooling system provides localized cooling to different regions of the battery pack through distributed cooling channels in the frame member. This allows tailored thermal management for cells in different locations, maintaining temperature uniformity even when cells are closely packed together.
Solution Approach 2:
The frame member acts as an intermediary thermal management system between the cells and the cooling fluid. It distributes heat uniformly from closely packed cells through integrated cooling channels, preventing temperature variations while maintaining high cell density.
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 modular design ensures efficient temperature regulation across cells, enhancing their lifespan and performance while simplifying assembly and reducing complexity.
Implementation Method 1
a cooling system that is integrally formed in the frame member... includes a coolant channel that is formed through the frame member and that connects the coolant inlet and outlet ports
Data Source
Figure 1
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AI summary
A battery pack includes a frame member (200), first and second lithium ion cells (400), and an isolation plate (404). The frame member (200) includes a floor (212), walls (204,208,216) formed perpendicular to the floor (212), and an aperture defined by the walls. The frame member is formed from an electrically non - conductive plastic. The first lithium ion cell (400) includes a first positive terminal, a first negative terminal, and a first electrically conductive housing. The first positive terminal is electrically connected to the first electrically conductive housing (104). The second lithium ion cell includes a second positive terminal, a second negative terminal, and a second electrically conductive housing. The second positive terminal is electrically connected to the second electrically conductive housing. The isolation plate directly contacts both the first and second electrically conductive housings and electrically isolates the first electrically conductive housing from the second electrically conductive housing. The isolation plate is formed from the electrically non - conductive plastic.