Battery Pack Mounting Structure With Integrated Cooling Channels
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Solution Overview
Problem
Conventional battery trays in electric vehicles fail to provide stable mounting and effective heat dissipation for battery modules, limiting the number of modules due to low volume-to-area ratio and inefficient space utilization.
Innovation Solution
A mounting structure that integrates a seating portion in the vehicle body's lower surface, a lower cover fixed to the vehicle body, and a heat sink with H-beam carriers forming flow paths for cooling water, allowing for efficient heat dissipation and stable mounting of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional battery tray is used, then the structure is simple, but the heat dissipation capability is insufficient and mounting stability is poor
Solution Approach 1:
The patent combines the battery tray, heat dissipation system, and mounting structure into an integrated assembly. The lower cover serves both as a structural support and as a mounting surface for the heat sink, while the carrier simultaneously holds battery modules and provides heat dissipation channels. This merging of functions resolves the contradiction by achieving effective heat dissipation without proportionally increasing structural complexity.
Solution Approach 2:
The lower cover is designed to perform multiple functions: it provides structural support for the battery pack, serves as a mounting base for the heat sink, and contributes to the overall heat dissipation pathway. The carrier similarly functions both as a structural element and as a heat dissipation component with integrated flow paths. This multi-functionality allows the system to achieve superior heat dissipation while maintaining reasonable structural complexity.
2Volume of moving object
If battery modules are mounted on the upper surface of the vehicle, then the mounting is simple, but the volume-to-area ratio is low and space utilization is inefficient
Solution Approach 1:
The patent transitions from mounting battery modules on the upper surface (two-dimensional arrangement) to positioning them in the lower space of the vehicle (utilizing three-dimensional space). The seating portion formed in the lower surface of the vehicle body creates a dedicated cavity that accommodates the battery pack, effectively using the vertical dimension and underbody space. This dimensional change significantly increases the volume-to-area ratio and improves space utilization while maintaining manufacturing feasibility through standardized assembly procedures.
3Quantity of substance
If the number of battery modules is increased, then the power capacity increases, but the heat dissipation challenge increases and mounting stability may be compromised
Solution Approach 1:
The patent divides the battery system into modular units (battery modules arranged in arrays) with corresponding segmented heat dissipation pathways. The carrier is divided into multiple sections, each with its own flow path for cooling fluid. This segmentation allows heat from multiple battery modules to be dissipated through distributed channels, maintaining heat dissipation efficiency even as the number of modules increases. The modular structure also facilitates stable mounting of larger numbers of modules.
4Reliability
If a simple tray structure is used, then the manufacturing cost is low, but the mounting stability and heat dissipation are insufficient
Solution Approach 1:
The patent merges the mounting structure and heat dissipation system into an integrated assembly where the lower cover serves dual purposes as both structural support and heat sink mounting base. This integration achieves reliable mounting stability through the unified structure while avoiding the need for separate complex mounting mechanisms, thereby controlling manufacturing 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
Enhances the volume-to-area ratio of battery modules, facilitates convenient assembly, and improves heat dissipation efficiency, thereby increasing the number of modules that can be mounted while maintaining structural integrity.
Implementation Method 1
a heat sink coupled to the carrier to face lateral side surfaces of the battery modules and to define a flow path through which cooling water flows
Data Source
AI summary
A mounting structure for a battery pack is provided. The mounting structure includes a battery pack having a plurality of battery modules, a carrier, which is positioned at the battery pack to be partitioned and to allow the battery modules to be mounted therein. A seating portion is formed in a vehicle body to define a pace for accommodating the battery pack therein. A lower cover is positioned on a lower surface of the battery pack, and a heat sink is coupled to the carrier to face lateral side surfaces of the battery modules and to define a flow path through which cooling water flows.