EV Battery Pack Structure With Flexible Cooling Plates
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Solution Overview
Problem
Existing electric vehicle battery packs face challenges in structural rigidity and cooling efficiency, particularly in supporting wire strain and heat dissipation within the battery module configuration.
Innovation Solution
The battery assembly incorporates upper and lower level modules with pillars, vertical and horizontal bolts for structural support, and cooling plates that extend longitudinally between rows of modules to enhance structural rigidity and heat dissipation, while a wire retention clip organizes electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules are arranged in multiple levels with pillars and bolts for structural support, then structural rigidity is improved, but device complexity increases
Solution Approach 1:
The battery pack is divided into upper and lower level modules arranged in a stacked configuration. Each level contains multiple battery modules that are independently structured but collectively form a rigid assembly. This segmentation allows the structure to achieve high rigidity through the distributed arrangement of modules connected by pillars and bolts, while maintaining manufacturing simplicity through modular assembly.
2Temperature
If cooling plates are added to enhance heat dissipation, then thermal management is improved, but device complexity increases
Solution Approach 1:
The cooling plates are integrated into the existing battery module structure, positioned between adjacent modules in the upper and lower levels. This merging approach allows the cooling system to utilize the same structural space and assembly pathways as the battery modules themselves, achieving effective thermal management without adding separate complex cooling infrastructure.
3Reliability
If wire retention clips are used to support electrical connections, then reliability is improved, but device complexity increases
Solution Approach 1:
The wire retention clips are designed to be self-installing components that snap into place within the battery module assembly process. The clips automatically secure the electrical wires and connectors to the battery modules without requiring additional fastening steps or complex alignment procedures, thereby improving connection reliability while maintaining simple assembly operations.
Data Source
AI summary
A vehicle battery assembly having a battery stack that includes a plurality of modules. The plurality of modules fastened by vertical and horizontal bolts. The battery stack includes cooling plates that is configured to be flexible and non-rigid placed between the modules. The cooling plates have improved isolation of structural stresses from the battery assembly.