Battery Pack Coolant Pipe Housing for Leak-Safe Module Cooling
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Solution Overview
Problem
Existing battery packs face challenges in maintaining effective cooling performance, particularly in large-sized modules used in vehicles, where heat generation is high and the risk of coolant leakage is significant, leading to potential explosions or ignitions.
Innovation Solution
A battery pack design incorporating a pack coolant pipe assembly housed within a pack coolant pipe housing with a lower part that can be opened, integrated with a module frame and heat sink, and a sealing system to prevent coolant leakage, including a gasket and drain valve, enhances cooling efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to form a battery module for high output, then capacity and output are improved, but heat generation increases and cooling becomes difficult
Solution Approach 1:
The battery pack is divided into multiple battery modules, each with its own cooling channels. The cooling system is segmented to provide targeted cooling to each module, allowing efficient heat dissipation from the high-power battery assembly without requiring a single complex cooling system.
Solution Approach 2:
A coolant (water or water-glycol mixture) is introduced as an intermediary substance to transfer heat from the battery cells to the cooling channels. The coolant circulates through the channels, absorbing heat from the battery modules and carrying it away, thus solving the heat generation problem enabled by high-power battery stacking.
2Temperature
If a water-cooled cooling structure is used to control increased heat generation, then cooling performance is improved, but the risk of coolant leakage to electrical components increases
Solution Approach 1:
The coolant is extracted from the potential leakage zone by introducing a drainage layer between the cooling channels and the electrical components. This drainage layer acts as a barrier that separates the coolant from the electrical components, allowing the water-cooled structure to maintain high cooling performance while preventing coolant from reaching electrical parts even if leakage occurs.
Solution Approach 2:
The drainage layer is installed beforehand as a protective measure between the cooling channels and electrical components. This pre-positioned barrier cushions against potential coolant leakage, preventing direct contact between coolant and electrical components before any leakage issue arises.
3Temperature
If cooling channels are formed between battery modules to improve cooling efficiency, then heat dissipation is improved, but the complexity of the cooling system structure increases
Solution Approach 1:
The cooling channels are merged with the existing battery module structure, utilizing the spaces between modules for coolant flow paths. This integration allows the cooling system to achieve efficient heat dissipation without adding separate complex cooling infrastructure, as the cooling channels are formed within the available structural spaces.
Solution Approach 2:
The battery module structure serves multiple functions: it houses the battery cells, provides structural support, and contains the cooling channels. This multi-functionality reduces overall system complexity by eliminating the need for separate dedicated cooling structures, as the battery module itself becomes part of the cooling system.
4Quantity of substance
If the battery pack is designed for high capacity with increased number of cells, then energy storage is improved, but the amount of heat generation increases requiring more sophisticated cooling
Solution Approach 1:
The high-capacity battery pack is segmented into multiple modules, each with integrated cooling channels. This segmentation allows the heat generated by the large number of cells to be distributed and managed locally in each module, preventing heat accumulation while maintaining high overall capacity.
Solution Approach 2:
A coolant circulation system is introduced as an intermediary heat transfer medium. The coolant flows through channels in the battery modules, absorbing the increased heat generation from the high-capacity cell arrangement and transporting it away from the battery pack, thus enabling high capacity operation without excessive heat buildup.
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 design improves cooling performance by ensuring uniform cooling across battery modules, reduces the risk of coolant leakage, and prevents electrical component damage, thereby enhancing the safety and efficiency of the battery pack.
Implementation Method 1
a water-cooled cooling structure rather than an air-cooled cooling structure is required to control the increased heat generation amount
Implementation Method 2
a water-cooled cooling structure rather than an air-cooled cooling structure is required to control the increased heat generation amount
Data Source
AI summary
A battery pack includes a battery module including a plurality of battery cells, a pack frame that houses the battery module, a pack coolant pipe assembly that is connected to the battery module, and a pack coolant pipe housing that houses the pack coolant pipe assembly therein and includes a lower part configurable between an open position and a closed position.