Battery Pack Frame Cooling Structure for Higher Energy Density
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Solution Overview
Problem
Rechargeable battery packs face limitations in energy capacity and require a simplified, strengthened, and lightweight frame and cooling structure to enhance energy density and thermal management.
Innovation Solution
A rechargeable battery pack design featuring a cell stack with a center frame and side frames that integrate cooling water paths, inflow and outflow balancers, and regression lines to simplify the structure, increase rigidity, and reduce weight while maximizing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are stacked directly without modules to maximize energy density, then energy capacity increases, but structural support and cooling become more difficult
Solution Approach 1:
The frame structure and cooling system are merged into a single integrated component. The frame includes internal channels that serve as cooling water paths, eliminating the need for separate cooling plates or modules. This integration maintains the simplified cell-stacking approach while providing both structural support and thermal management functions.
2Temperature
If traditional separate frame and cooling plate structures are used, then cooling function is provided, but weight and structural complexity increase
Solution Approach 1:
The cooling plates are merged with the frame structure to form an integrated component. The frame includes internal channels that serve as cooling water paths, eliminating the need for separate cooling plates. This integration reduces the total number of parts and overall weight while maintaining effective cooling functionality.
3Ease of manufacture
If multiple separate components are used for frame and cooling, then manufacturing is easier, but assembly complexity and structural rigidity decrease
Solution Approach 1:
The frame and cooling system are merged into a single integrated component that can be manufactured as one piece using extrusion or casting processes. This integration eliminates assembly steps between separate frame and cooling plate components while significantly improving structural rigidity and strength throughout the battery pack housing.
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 frame and cooling structure enhances the battery pack's energy density, simplifies the design, strengthens the rigidity, and reduces weight, effectively addressing the limitations of existing rechargeable battery packs.
Implementation Method 1
a plurality of cooling water paths extending in the first direction and spaced a distance from each other in the second direction
Implementation Method 2
The first floor and the second floor include a plurality of cooling water paths extending in the first direction
Implementation Method 3
an inflow balancer that connects inlets of the cooling water path to balance the inflow cooling water flow
Implementation Method 4
an outflow balancer that connects outlets of the cooling water path to balance the outflow cooling water flow
Data Source
AI summary
A rechargeable battery pack includes: a cell stack including a plurality of battery cells stacked in a first direction; a center frame integrally forming a first floor and a first sidewall and supporting the cell stack; and a first side frame and a second side frame integrally forming a second floor coupled to the first floor in a second direction crossing the first direction and a second side wall supporting narrow cell side surfaces of the cell stack. The first floor and the second floor include a plurality of cooling water paths extending in the first direction and spaced a distance from each other in the second direction.