Battery Housing Cooling Channel Bonding for Leak-Tight Traction Packs
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Solution Overview
Problem
Battery housings made of plastic face challenges in maintaining fluid-tightness and mechanical stability under thermal and mechanical stresses, leading to coolant leakage and potential damage to battery components.
Innovation Solution
A battery housing component comprising a base component made of a first plastic, a fiber-reinforced connecting component, and a multilayer film, with a bonding layer of fiberless thermoplastic polymer, forming a cooling fluid channel that enhances stability and prevents leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fluid channels are arranged within a plastic battery housing, then heat dissipation is improved, but fluid-tightness deteriorates leading to leakage under pressure
Solution Approach 1:
The patent employs a composite structure consisting of a plastic housing component combined with a metal cooling plate. The metal plate provides the cooling fluid channels with high pressure resistance and fluid-tightness, while the plastic housing provides insulation and structural support. This composite material approach resolves the contradiction by combining materials with complementary properties to achieve both heat dissipation and leakage prevention.
Solution Approach 2:
The invention merges the housing function and cooling function into a single integrated component. The metal cooling plate is permanently bonded to the plastic housing, creating a unified structure where the cooling channels are formed by the metal plate while the plastic housing provides thermal insulation and mechanical protection. This merging eliminates the leakage issue while maintaining effective heat dissipation.
2Temperature
If battery housing is made of plastic for insulation, then thermal insulation is improved, but mechanical strength and pressure resistance deteriorate
Solution Approach 1:
The patent uses a composite construction combining plastic and metal materials. The plastic housing provides thermal insulation to protect battery components from excessive heat, while the metal cooling plate provides the necessary mechanical strength and pressure resistance to withstand cooling fluid pressure. This composite material strategy simultaneously achieves both thermal insulation and structural strength.
3Device complexity
If cooling channels are integrated into housing for compactness, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The invention combines the housing and cooling system into a single integrated component through permanent bonding of the metal cooling plate to the plastic housing. This merging reduces device complexity by eliminating separate cooling system components while the standardized bonding process manages manufacturing precision requirements through proven joining techniques.
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 a robust cooling fluid channel that withstands higher pressures, protecting battery components from coolant contact and improving operational reliability while maintaining a compact design.
Implementation Method 1
The bonding surface of the multilayer film is materially bonded to the outer surface of the fiber-reinforced connecting component by means of a bonding layer made of a fiberless thermoplastic polymer
Implementation Method 2
Heat is generated during both the charging and discharging of these battery components. Since the battery components have a thermal operating window within which charging and discharging function optimally, the heat generated by the battery components must be dissipated through the battery casing
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
The invention discloses a battery housing component (10) for a traction battery for cooling at least one battery component (11), wherein the battery housing component (10) has a base part (20), which comprises a first plastic, a fibre-reinforced connecting part (30), which has a connecting-part inner surface (31) and a connecting-part outer surface (32), and a multilayer film (40), wherein the multilayer film (40) has a connecting surface (41) and a contacting surface (42), wherein the contacting surface (42) is designed for at least indirectly contacting the at least one battery component (11), wherein the fibre-reinforced connecting part (30) is arranged in a sandwich-like manner between the base part (20) and the multilayer film (40), wherein a base-part inner surface (21) of the base part (20) is integrally bonded to the connecting-part inner surface (31), and wherein the connecting surface (41) of the multilayer film (40) is integrally bonded to the connecting-part outer surface (32) of the fibre-reinforced connecting part (30) so as to form at least one cooling fluid channel (50), arranged between the multilayer film (40) and the connecting part (30), for conducting a cooling fluid by means of a connecting layer (60) made of a fibre-free thermoplastic.