Battery Pack Support Assembly With Integrated Cooling Channels
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Solution Overview
Problem
Conventional battery packs for electric vehicles face issues of insufficient cooling, complex assembly, high weight, and increased manufacturing costs due to multiple components for cooling, electrical connection, and structural resistance, which limit energy density and reliability.
Innovation Solution
A battery pack structural assembly featuring transverse support devices with integrated cooling channels and electrical interconnection plates, made from a polymer material with reinforcement, providing efficient cooling and structural rigidity while reducing assembly complexity and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional metallic housing with separate cooling plate and thermal interface material is used, then cooling function is provided, but assembly complexity and manufacturing costs increase
Solution Approach 1:
The patent combines the cooling plate and thermal interface material functions into an integrated support structure. The support structure includes cooling channels formed directly within the structural elements, eliminating the need for separate cooling plates and thermal interface materials. This merging of functions reduces the number of components and simplifies assembly while maintaining effective heat dissipation.
Solution Approach 2:
The support structure serves multiple functions simultaneously: it provides structural support and rigidity, enables cooling through integrated channels, and facilitates electrical connection through conductive elements. This multi-functionality eliminates the need for separate dedicated components for each function, reducing assembly complexity and manufacturing costs.
2Reliability
If multiple assembly components for cooling and electrical connection are used, then functional requirements are met, but manufacturing costs increase
Solution Approach 1:
The patent merges cooling channels and electrical connection elements into a single integrated support structure. The support structure includes both cooling channels and conductive elements that serve dual purposes, eliminating the need for separate cooling plates, thermal interface materials, and electrical connection components. This integration reduces the total number of parts and associated manufacturing costs.
Solution Approach 2:
The support structure is designed to perform multiple functions: structural support, cooling through integrated channels, and electrical connection through conductive elements. This multi-functionality allows a single component to replace multiple separate components, reducing manufacturing complexity and cost while maintaining all required functional capabilities.
3Strength
If conventional metallic housing with reinforcing elements is used, then structural integrity is improved, but weight increases
Solution Approach 1:
The patent employs composite materials in the support structure, combining materials with different properties to achieve both structural integrity and weight reduction. The support structure uses materials that provide both mechanical strength and thermal conductivity, replacing conventional metallic housing with a optimized composite construction that maintains strength while reducing weight.
Solution Approach 2:
The support structure is segmented into functional zones with different material properties optimized for specific functions. Different regions of the support structure use materials or configurations tailored for structural support, thermal management, or electrical connection, allowing weight optimization in each zone while maintaining overall structural integrity.
4Shape
If casing with high structural rigidity is used, then crash resistance is improved, but volume increases
Solution Approach 1:
The support structure is segmented into a three-dimensional lattice or framework configuration that provides high structural rigidity relative to its volume. This segmented architecture distributes mechanical loads efficiently throughout the structure, achieving crash resistance without requiring a solid bulky casing, thus reducing overall battery pack volume.
Solution Approach 2:
The support structure uses composite materials with high strength-to-volume ratios, such as fiber-reinforced polymers or advanced metal composites, that provide high structural rigidity in a compact form. These materials enable the achievement of required crash resistance with reduced material volume compared to conventional metallic housings.
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 solution enables a compact, lightweight, and robust battery pack with high energy density, efficient cooling, and reduced manufacturing costs, suitable for automotive applications with enhanced crash resistance.
Implementation Method 1
ensure sufficient heat flow from the battery cells to the cooling element, it is known to provide a thermal interface material inserted between battery cells and the cooling element to improve contact and heat flow through conduction
Implementation Method 2
circulation of cooling fluid through the transverse support device
Data Source
AI summary
Battery pack structural assembly (2) comprising a plurality of transverse support devices (5) between which one or more groups of stacked battery cells (3) may be mounted and electrically interconnected, each transverse support device comprising a support frame (6) and a plurality of battery connection plates (16) mounted on the support frame, the battery connection plates having a conductive surface facing an outer side of the transverse support, the support frame comprising chambers (8) formed therein interconnected fluidically to form at least one channel for circulation of cooling fluid through the transverse support device, the chambers being covered by the battery connection plates.