Battery Pack Mounting Plate with Integrated Refrigerant Channels
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Solution Overview
Problem
Large capacity battery packs used in electric vehicles face challenges with increased manufacturing costs and reduced energy density due to separate cooling members, and safety issues from refrigerant leaks causing electric short circuits during impacts.
Innovation Solution
A battery pack design with an integrated cooling system where the mounting plate includes refrigerant channels, feed and discharge pipes, and a tray structure that eliminates the need for separate cooling members, enhancing cooling efficiency and protecting against impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate cooling members are used for large capacity battery packs, then cooling capability is improved, but manufacturing cost and assembly cost increase
Solution Approach 1:
The cooling channels are integrated directly into the mounting plate structure, merging the cooling function with the structural support function. This eliminates the need for separate cooling members, reducing manufacturing cost and assembly complexity while maintaining effective cooling capability for large capacity battery packs
2Temperature
If separate cooling members are used for large capacity battery packs, then cooling capability is improved, but energy density is reduced
Solution Approach 1:
By integrating the cooling channels into the mounting plate, the volume occupied by separate cooling members is eliminated. This increases the space available for battery modules, thereby improving energy density while maintaining adequate cooling capability
3Temperature
If separate cooling members are used, then cooling function is achieved, but safety is reduced due to refrigerant leaks during impacts
Solution Approach 1:
The cooling channels are formed as an integral part of the mounting plate structure rather than as separate components. This eliminates joints and connections that could leak refrigerant, significantly improving safety by preventing refrigerant leaks during vehicle impacts while maintaining the cooling function
Solution Approach 2:
The integrated structure inherently provides impact resistance before impacts occur. The mounting plate's rigid structure protects the cooling channels from damage and prevents refrigerant leaks during collisions, addressing safety concerns proactively
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 system reduces manufacturing costs, improves safety by preventing refrigerant leaks, and enhances cooling efficiency, while maintaining energy density.
Implementation Method 1
the mounting plate includes a plurality of refrigerant channels, each refrigerant channel extending from one side to the other side and being in communication with the feed pipe or the discharge pipe
Data Source
AI summary
A battery pack includes a plurality of battery modules and a tray including a mounting plate which extends horizontally so that the plurality of battery modules are mounted on the mounting plate. The mounting plate includes a feed pipe disposed on one side and configured to receive a refrigerant from outside, and the mounting plate includes a discharge pipe disposed on the other side and configured to discharge the refrigerant to the outside. The mounting plate includes a plurality of refrigerant channels, each refrigerant channel extending from the one side to the other side and being in communication with the feed pipe or the discharge pipe. The battery pack desirably reduces manufacturing cost and improves safety by reducing the number of components and simplifying the assembly process.