Thermo-Structural Battery Pack Frames for Leak-Safe Cooling
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Solution Overview
Problem
Existing battery enclosures fail to optimize structural and thermal performance, leading to issues such as coolant leaks causing thermal runaway, passive cooling resulting in overheating, and increased weight and manufacturing complexity, while not acting as a structural component.
Innovation Solution
Integrated metal alloy frames with thermo-structural features, incorporating coolant compartments, venting systems, and modular sub-packs that provide efficient thermal regulation and structural support, allowing for interchangeable and stackable battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate cold plate and enclosure design is used with coolant in direct contact with battery cells, then thermal management is achieved, but coolant leaks at welded seams cause thermal runaway
Solution Approach 1:
The patent extracts the coolant from direct contact with battery cells by introducing a thermal interface material layer between them. This separation prevents coolant leaks from causing direct contamination of battery cells, eliminating the domino effect failure mode while maintaining thermal management through the interface material's thermal conductivity.
Solution Approach 2:
The patent introduces a thermal interface material as an intermediary substance between the coolant and battery cells. This mediator transfers heat effectively while preventing direct contact between coolant and cells, thus maintaining thermal management safety even when coolant leaks occur at welded seams.
2Device complexity
If passive cooling is used in existing battery enclosures, then simple design is achieved, but circuit overheating occurs
Solution Approach 1:
The patent implements self-service thermal management through the thermal interface material that passively conducts heat from battery cells to the coolant system without requiring active control mechanisms. The system automatically regulates temperature through the inherent thermal conductivity of the interface material and coolant flow.
3Strength
If cover and tub methodology with extrusion frames is used, then structural enclosure is achieved, but high number of fasteners increases manufacturing complexity
Solution Approach 1:
The patent merges the cover and tub components into a single integrated enclosure structure with built-in structural features. This consolidation eliminates the need for multiple separate fasteners by incorporating interlocking elements and integrated attachment points directly into the molded enclosure design.
4Strength
If load bearing modules with high aspect ratios are used, then structural support is achieved, but low torsional and bending stiffness creates integration difficulty
Solution Approach 1:
The patent enhances the structural performance of load-bearing modules by adding dimensional features such as ribs, flanges, and three-dimensional reinforcement structures. These geometric modifications increase torsional and bending stiffness without significantly increasing the module's footprint or aspect ratio, making integration easier while maintaining load-bearing capacity.
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
Enhances battery efficiency, safety, and longevity by preventing thermal runaway, reducing weight, and simplifying manufacturing, while adapting to various product designs and regulatory requirements.
Implementation Method 1
integrally formed (for example, cast) alloy frames manufactured to incorporate various structural and thermal features into a single part
Implementation Method 2
coolant compartments formed in an exterior surface of the enclosure
Data Source
AI summary
Thermally managed electric vehicle battery packs and systems comprising a battery sub-packs designed to mate and coupled together such that the sub-packs define a battery cell compartment comprising a first set of battery cells and a second set of battery cells. The sub-packs can comprise integrated coolant compartments, ancillary compartments, or both. The sub-packs can comprise casted metal alloy frames defining various components of the battery packs. The battery packs and systems can comprise a stackable architecture that facilitates, among other things, efficient manufacturing of packs that can be stacked together, and efficient thermal regulation and space utilization in products.