Battery Pack Cooling via Linear Airflow Path
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Solution Overview
Problem
Existing battery packs lack effective cooling functionality and have a larger longitudinal length, which can hinder heat dissipation and increase size.
Innovation Solution
A battery pack design featuring a thermally conductive housing with cooling fins and a heat exchanger that directs airflow in a linear path to enhance heat transfer, combined with electric fans to circulate air through the pack, reducing longitudinal length while improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional battery pack design is used, then the battery pack can be manufactured with simple structure, but the cooling functionality is insufficient and longitudinal length is larger
Solution Approach 1:
The patent integrates the heat exchanger beneath the battery module, utilizing the vertical dimension (height) rather than extending the longitudinal length. The heat exchanger's cooling fins extend upward into the battery pack housing, creating a three-dimensional heat dissipation structure that improves cooling without increasing the pack's length.
Solution Approach 2:
The heat exchanger is nested within the battery pack housing structure, with the first housing portion positioned between the battery module and the bottom wall. This nested arrangement allows the cooling system to be embedded within the existing structure, eliminating the need for additional longitudinal space.
2Temperature
If cooling fins are added to enhance heat dissipation, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The heat exchanger is integrated with the battery pack housing as a single unit, where the first housing portion forms part of the housing structure itself. The cooling fins are attached to this integrated housing portion, combining the housing and heat exchanger functions into one component rather than using separate pieces.
Solution Approach 2:
The first housing portion serves multiple functions: it provides structural support as part of the battery pack housing, acts as a thermal conduit from the battery module, and supports the cooling fins for heat dissipation. This multi-functionality reduces the need for additional components.
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 airflow and cooling functionality, effectively transferring heat from the battery module and housing to air, resulting in a more compact and efficient cooling system.
Implementation Method 1
The first electric fan urges air to flow through the inlet aperture, the first flow path portion, the second flow path portion, and through the first electric fan to the first outlet aperture to cool the battery module
Implementation Method 2
The first heat exchanger is disposed against one another [with the battery cell]. The thermally conductive housing has cooling fins coupled to and extending upwardly... to transfer heat from the battery module
Implementation Method 3
air flow through the inlet aperture, the first flow path portion, the second flow path portion... to cool the battery module
Data Source
AI summary
A battery pack has a battery pack housing that defines an interior region, and a battery module that is disposed in the interior region. The battery module has a first battery cell, and a first heat exchanger defining a first flow path portion therethrough. The battery pack further includes a first electric fan and a thermally conductive housing that are disposed in the interior region. The thermally conductive housing has a first housing portion, and at least first and second cooling fins defining a second flow path portion therebetween. At least a portion of the second flow path portion is substantially in-line with the first flow path portion. The first electric fan urges air to flow through an inlet aperture, the first flow path portion, the second flow path portion, and through the first electric fan to a first outlet aperture to cool the battery module.