Integrated Battery Pack Cooling Structure for Easier Cell Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery pack configuration requires a separate tube member for connecting adjacent coolers, leading to increased complexity and cost in assembly.
Innovation Solution
A battery pack design with an integrated cooling device where coolers are joined to form a deformable structure, allowing the cooling surface to adjust based on pressure changes, facilitating assembly by reducing the need for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate tube member is used to connect adjacent coolers, then the cooling device can be assembled, but the number of components increases and assembly complexity increases
Solution Approach 1:
The patent merges the tube member and cooler into a single integrated structure where the tube portion is formed as an integral part of the cooler body. This eliminates the need for separate connecting members between adjacent coolers, reducing component count and assembly complexity while maintaining the cooling function.
Solution Approach 2:
The cooler is designed with multi-functionality: it provides cooling through its cooling surface that contacts battery cells, and simultaneously serves as a connecting structure through its tube portion that integrates with adjacent coolers. This universal design eliminates the need for dedicated connecting components.
2Temperature
If the cooling surface is in contact with the battery cell, then effective cooling is achieved, but insertion of the battery cell becomes difficult
Solution Approach 1:
The cooler incorporates a deformable diaphragm portion that can dynamically change its shape and position. During assembly, the diaphragm can be depressed to create insertion space, and during operation, it can return to its original position to ensure thermal contact with the battery cell, thus adapting to different operational requirements.
Solution Approach 2:
The diaphragm portion is pre-designed with deformability characteristics that allow it to be temporarily displaced during the insertion process. This preliminary deformation creates the necessary clearance for battery cell insertion, after which the diaphragm naturally returns to its cooling contact position.
3Ease of manufacture
If the cooler is made deformable to adjust cooling surface position, then assembly is facilitated, but the structure becomes more complex
Solution Approach 1:
The diaphragm portion is constructed as a flexible thin-walled structure that can deform under pressure differential. This flexible film approach enables the cooler to change its configuration during assembly without requiring complex mechanical actuation mechanisms, keeping the overall structure relatively simple.
Solution Approach 2:
The deformation of the diaphragm portion is achieved through pressure differential (negative pressure applied to the outer surface) rather than mechanical actuators. This pneumatic approach simplifies the structure by using pressure control instead of complex mechanical deformation mechanisms.
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 integrated cooling device simplifies assembly and reduces costs by eliminating the need for additional connecting members, while ensuring effective cooling through deformable coolers that adapt to pressure changes.
Implementation Method 1
the cooler is deformable so as to displace the cooling surface in the first direction in accordance with a pressure inside the cooler
Implementation Method 2
a cooling device, provided inside the case, for cooling the battery cells with a coolant... a flow path that allows the coolant to circulate; and a cooling surface that comes in contact with the battery cells
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A battery pack 1 includes: a plurality of battery cells 2; a case 3 accommodating the plurality of battery cells 2; and a cooling device 4 provided inside the case 3 to cool the battery cells 2 with a coolant. The cooling device 4 includes a plurality of coolers 10. The cooler 10 includes: a flow path 13 that allows the coolant to circulate; and a cooling surface 10a that comes in contact with the battery cells 2. The plurality of coolers 10 and the plurality of battery cells 2 are alternately stacked in an X direction inside the case 3. The cooling device 4 is an integrated structure in which the plurality of coolers 10 is joined with each other. The cooler 10 is deformable so as to displace the cooling surface 10a in the X direction in accordance with a pressure inside the cooler 10.