Battery Pack Cooling Structure for Heat and Vibration Stability
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Solution Overview
Problem
Rechargeable batteries generate heat during charging and discharging, which can lead to damage and require effective heat dissipation and fixation against shock and vibration.
Innovation Solution
A rechargeable battery pack design featuring a battery housing with a lower holder unit that fixes and cools unit battery cells using a cooling unit, bus bars, and insulating thermal glue for efficient heat transfer and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a plurality of unit battery cells are connected to increase capacity, then the battery capacity increases, but heat generation increases and requires more effective cooling
Solution Approach 1:
The cooling unit is divided into multiple cooling channels that correspond to individual battery cells or groups of cells. Each cooling channel independently cools specific battery cells, allowing distributed heat dissipation across the battery pack. This segmentation enables effective cooling of high-capacity battery packs with multiple cells without requiring a single large cooling system.
2Strength
If the lower holder unit is formed integrally with the bottom plate to fix battery cells, then the fixation strength increases, but heat dissipation efficiency may be compromised
Solution Approach 1:
The lower holder unit is formed integrally with the bottom plate at specific locations where fixation is needed, rather than making the entire bottom plate a holder. This integral formation provides strong fixation points while maintaining thermal conductivity pathways through the bottom plate to the cooling unit. The local integral formation allows simultaneous achievement of mechanical strength and heat dissipation by concentrating structural reinforcement only where battery cell fixation is required.
3Temperature
If thermal glue is used to fill between the holder and battery cells, then thermal conduction improves, but electrical insulation must be maintained
Solution Approach 1:
An electrically insulating thermal glue with high thermal conductivity is used to fill the gaps between the lower holder unit and battery cell terminals. This composite material simultaneously provides thermal conduction pathways for heat dissipation and electrical insulation to prevent short circuits. The thermal glue creates a dual-function interface that addresses both heat transfer and electrical isolation requirements in the battery pack assembly.
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 effectively cools and stabilizes the battery cells, improving durability and driving stability by preventing heat damage and maintaining electrical insulation.
Implementation Method 1
a cooling unit in a bottom plate of the battery housing under the lower holder unit to cool the unit battery cells
Implementation Method 2
The filler may be an electrically insulating thermal glue
Data Source
AI summary
A rechargeable battery pack includes: a battery housing including an inner space; a plurality of unit battery cells in the inner space; a bus bar configured to electrically connect unit battery cells of the plurality of unit battery cells; a lower holder unit configured to fix the unit battery cells in the battery housing; and a cooling unit in a bottom plate of the battery housing under the lower holder unit to cool the unit battery cells.