Battery Pack Airflow Frame and Baffles for Sealed Cooling
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Solution Overview
Problem
Existing battery packs face challenges in effectively managing thermal cooling and airflow within a sealed housing, which can lead to inefficiencies and potential overheating of battery cells.
Innovation Solution
A battery pack assembly with a housing, battery cell assembly, and fan configuration that includes a frame supporting battery cells, airflow tunnels, and baffles to direct airflow, along with a heat sink to manage thermal cooling and airflow within a sealed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a battery pack is designed to fit into a specific space with a defined maximum filling factor, then the space utilization is improved, but the battery capacity is limited
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing several battery cells. This segmentation allows flexible arrangement of modules to optimize space utilization while maintaining high capacity through parallel series configurations of multiple modules
Solution Approach 2:
The battery modules are arranged in a multi-dimensional configuration within the housing, utilizing vertical and horizontal space efficiently. The modules can be stacked or positioned in layers to maximize the filling factor without compromising individual cell capacity
2Volume of moving object
If battery modules are arranged to maximize space utilization, then the volume efficiency is improved, but the thermal management becomes more challenging
Solution Approach 1:
Different regions of the battery pack are designed with different thermal management characteristics. Modules experiencing higher heat generation are positioned near better cooling channels, while modules with lower heat generation are placed in regions with reduced cooling requirements
Solution Approach 2:
A thermal management system with cooling channels and heat dissipation structures is introduced as an intermediary between the battery modules and the environment. This system facilitates efficient heat transfer from densely packed modules without requiring excessive spacing
3Ease of manufacture
If the battery pack structure is simplified to reduce manufacturing complexity, then the ease of manufacture is improved, but the adaptability to different battery configurations is reduced
Solution Approach 1:
The housing and module designs incorporate universal connection interfaces and standardized mounting structures that can accommodate different numbers and arrangements of battery modules. The same basic housing design can adapt to various configurations by simply adding or removing modules without requiring custom tooling or complex assembly procedures
Data Source
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AI summary
A battery pack assembly includes a housing, a battery cell assembly, and a fan. The housing having a plurality of sides and defining an internal cavity. The battery cell assembly positioned in the internal cavity. The battery cell assembly includes a plurality of battery cells and a frame supporting the battery cells. The frame includes a first support member, a second support member, and a plurality of leg members connecting the first support member and the second support member. The first support member and the second support member each has a body extending between a first edge and a second edge opposite the first edge. The body defines a plurality of openings configured to align with one of the battery cells. The fan is configured to circulate air within the housing and through the battery cell assembly.