Battery Pack Frame With Integral Cooling Circuit for Simpler Assembly
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Solution Overview
Problem
Conventional battery packs for vehicles have a complex thermal management system with many parts, which increases assembly effort and costs, and makes replacement of defective components cumbersome due to the numerous interconnected components in the liquid cooling circuit.
Innovation Solution
The battery pack integrates a liquid cooling circuit into the frame profile, using the frame as a coolant distribution and collection structure, reducing the number of separate components and simplifying manufacturing, while maintaining structural integrity and thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional liquid cooling circuit with separate components is used, then thermal management function is provided, but assembly effort increases and number of parts increases
Solution Approach 1:
The cooling circuit components are integrated into the frame profile itself. The frame profile includes coolant supply channels and collection channels formed as integral parts of the frame structure, eliminating the need for separate cooling pipes and manifolds. This merging of functions reduces the number of parts while maintaining the thermal management capability.
Solution Approach 2:
The frame profile serves multiple functions simultaneously: it provides structural support for the battery modules and contains integrated cooling circuit functionality. The frame acts as both a mechanical framework and a coolant distribution system, reducing overall system complexity.
2Reliability
If a conventional liquid cooling circuit with many interconnected components is used, then cooling function is achieved, but replacement of defective components becomes cumbersome
Solution Approach 1:
By integrating the cooling channels into the frame profile as a single integral component, the system eliminates multiple connection points and interfaces. This reduces the complexity of component replacement, as the frame with integrated cooling can be replaced as a single unit or the cooling function is inherently more reliable with fewer potential failure points.
3Temperature
If separate cooling plates and pipes are used, then thermal contact with battery modules is achieved, but assembly effort increases
Solution Approach 1:
The cooling supply channels and collection channels are formed as integral parts of the frame profile structure. This eliminates the need for separate cooling plates and pipes, significantly reducing assembly steps while maintaining effective thermal contact with the battery modules through the frame's direct contact points.
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 integration reduces assembly effort, minimizes the number of parts, and ensures robust cooling without increasing the battery pack's weight, allowing for efficient temperature distribution across all battery modules and facilitating easier replacement of components.
Implementation Method 1
a liquid cooling circuit including one or more cooling plates being in thermal contact with the battery module
Data Source
AI summary
The present invention relates to a battery pack including a frame profile with integral coolant circuit elements. The battery pack includes one or more battery modules, each comprising a plurality of secondary battery cells, a framework comprising a first frame profile and a second frame profile opposite to the first frame profile, and a liquid cooling circuit comprising one or more cooling plates being in thermal contact with the battery module.