Roll-Bonded Battery Pack Housing With Cooling and Crash Channels
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Solution Overview
Problem
Existing battery packs face challenges in efficient thermal management, impact resistance, and assembly complexity, leading to increased costs and burdensome maintenance due to the need for additional cooling plates and crash protection components.
Innovation Solution
A battery pack design incorporating a housing formed by roll-bonded metal sheets with integrated cooling and crash channels, where cooling channels are formed between bonding areas and crash channels are formed in unbonded areas, reducing the number of assembly parts and enhancing thermal management and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional cooling plates and crash protection components are added to the battery pack, then thermal management and impact resistance are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent merges the housing structure with cooling channels and crash protection channels into a single integrated component. The housing includes internally formed cooling channels for thermal management and crash channels for impact protection, eliminating the need for separate cooling plates and crash protection components. This integration directly resolves the technical contradiction by maintaining reliability while reducing device complexity.
Solution Approach 2:
The housing is designed as a multi-functional component that simultaneously provides structural enclosure, thermal management through integrated cooling channels, and crash protection through integrated crash channels. This universal design allows a single component to perform multiple functions that traditionally required separate parts, thereby reducing assembly complexity while maintaining all necessary protective and functional capabilities.
2Reliability
If traditional separate components for cooling and crash protection are used, then functional requirements are met, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The housing combines multiple functional requirements into a single manufactured component. The cooling channels and crash channels are formed as integral parts of the housing structure through processes such as injection molding or extrusion, eliminating the need to manufacture and assemble separate cooling plates and crash protection components. This integration reduces both manufacturing costs and assembly complexity while meeting all functional requirements.
Solution Approach 2:
The cooling channels and crash channels are formed during the housing manufacturing process itself, rather than being added as post-processing steps. The channel geometries are built into the housing structure during initial fabrication, allowing subsequent assembly operations to focus only on installing battery modules and electrical connections. This preliminary formation of channels significantly reduces overall assembly complexity.
3Stability of the object's composition
If battery modules are fixed with mechanical interconnectors and fastening plates, then structural stability is achieved, but assembly complexity increases
Solution Approach 1:
The housing serves as both the structural enclosure and the mounting structure for battery modules. The integrated design allows battery modules to be directly secured to the housing walls and bottom using simple fasteners, eliminating the need for separate carrier frameworks, mechanical interconnectors, and side plates. This merging of structural and mounting functions maintains structural stability while reducing assembly complexity.
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 achieves improved thermal performance and impact protection with reduced manufacturing complexity and costs by integrating cooling and crash channels directly into the housing without additional parts, enhancing the battery pack's structural integrity and safety.
Implementation Method 1
at least one among the plurality side walls, the top member and the bottom member includes a plurality of metal sheets which are roll-bonded to each other
Data Source
AI summary
A battery pack according to one or more embodiments of the present disclosure includes a plurality of battery cells; and a housing including a bottom member, a plurality of side walls, and a top member, the bottom member, the plurality of side walls, and the top member form an interior accommodation space configured to accommodate the plurality of battery cells, wherein at least one among the plurality side walls, the top member, and the bottom member are formed by a plurality of metal sheets that are roll bonded to each other, wherein at least one cooling channel is formed between bonding areas of the plurality of metal sheets, and wherein at least one crash channel is formed between bonding areas of the plurality of the metal sheets.