Integrated Battery Pack Cooling Block Design
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Solution Overview
Problem
Existing battery packs for environmentally-friendly vehicles face issues with space utilization, manufacturability, and electrical safety due to separate manufacturing of the cartridge and cooling block, leading to potential insulation breakdown and increased risk of electrical hazards.
Innovation Solution
A battery pack design where the cooling block is integrated into a housing with cell insertion parts, upper and lower plates, and side plates, forming a cohesive unit that supports and cools battery cells without a separate cartridge, using a snap-fit connection for assembly and thermal fusion for bonding, thereby maximizing space and reducing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cartridge and cooling block are separately manufactured, then the assembly structure is simple, but the space utilization is reduced and manufacturability is deteriorated
Solution Approach 1:
The cartridge and cooling block are merged into a single integrated component where the cooling block is positioned within the cartridge structure. This integration eliminates the need for separate manufacturing and assembly of two distinct parts, thereby improving space utilization while maintaining manufacturability through unified production processes.
2Reliability
If the cartridge and cooling block are separately manufactured, then the assembly process is simplified, but the insulation reliability is reduced due to potential contact between battery cells and cooling block
Solution Approach 1:
The cooling block is nested within the cartridge structure, with the cartridge forming an outer shell that surrounds the cooling block. This nested arrangement ensures that the battery cells are isolated from direct contact with the cooling block by the cartridge's insulating material, thereby maintaining insulation reliability while integrating the functions of both components.
3Strength
If the cartridge and cooling block are separately manufactured, then the production flexibility is improved, but the durability against external impact is reduced
Solution Approach 1:
The cartridge and cooling block are combined into a single integrated component with the cooling block positioned inside the cartridge. This integration creates a unified structure that provides better mechanical protection against external impacts, as the cartridge's outer shell protects the cooling block and battery cells simultaneously, while production flexibility is maintained through efficient molding processes.
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 design enhances durability against external impacts, improves insulation for electrical safety, and optimizes cooling performance while minimizing the number of parts, thus reducing manufacturing costs and improving manufacturability.
Implementation Method 1
a cooling block cooling the battery cells
Implementation Method 2
using a snap-fit connection for assembly
Implementation Method 3
thermal fusion for bonding
Data Source
AI summary
Disclosed is a battery back that includes a housing that has a receiving space formed within, battery cells accommodated in the receiving space and supported by the housing, and a cooling block that is accommodated in the receiving space. The cooling block includes cell insertion parts. The cell insertion parts include a top opening and a bottom opening, such that the battery cells are inserted into the cell insertion parts and a cooling chamber in which cooling water flows. The cooling block also includes an upper plate coupled to upper end portions of the cell insertion parts, a lower plate coupled to lower end portions of the cell insertion parts, and a pair of side plates that connects the upper plate and the lower plate.