Vehicle Battery Pack Coupling Member with Integral Cooling Channels
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Solution Overview
Problem
Existing battery pack cooling systems face challenges in assembly complexity, tightness, and mechanical fixation, particularly due to the increased number of parts and critical tolerances, which complicate automation and may lead to connection deterioration during daily operation.
Innovation Solution
A battery pack design featuring a coupling member with integral cooling channels and a coolant distributor, utilizing self-locking clamp elements and mounting brackets for secure mechanical and fluid connections, eliminating the need for additional fixation means like screws, ensuring durable and robust attachment and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cooling circuit components are used with separate fixation means, then mechanical connection is achieved, but assembly complexity increases and tightness cannot be ensured
Solution Approach 1:
The patent combines the coolant distributor and coupling member into a single integrated component. The coupling member includes both the fluid distribution function and the mechanical coupling function, eliminating the need for separate fixation means such as screws or clamps. This merging of functions reduces the number of parts while ensuring reliable tightness through the integrated design of the coupling elements.
2Strength
If multiple fixation means are used to secure cooling circuit components, then mechanical connection strength is improved, but assembly process becomes more complex and automation difficult
Solution Approach 1:
The coupling member incorporates self-locking coupling elements that automatically secure the coolant distributor to the carrier plate without requiring additional fixation means. The self-locking mechanism provides sufficient mechanical connection strength while enabling simple, automated assembly processes, as the components self-assemble through the inherent locking action of the coupling elements.
3Reliability
If critical tolerances are maintained for connection tightness, then connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The integrated coupling member design changes the connection parameters by providing built-in tolerance compensation through the self-locking coupling elements. The design allows for greater manufacturing tolerances while maintaining connection tightness, as the coupling elements are designed to accommodate dimensional variations and still achieve reliable fluid-tight connections without requiring critical precision.
4Adaptability or versatility
If separate components are used for cooling circuit assembly, then adaptability is improved, but device complexity and assembly time increase
Solution Approach 1:
By merging the coolant distributor and coupling member into a single integrated component, the patent reduces assembly time while maintaining adaptability. The integrated design allows the cooling circuit to be assembled as fewer pre-configured modules, reducing the number of assembly steps and time required, while the modular nature of the battery pack system preserves configurability for different applications.
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 provides a simplified assembly process, ensures fluid-tight and mechanical fixation during daily operation, and can withstand mechanical loads such as vibration, maintaining connection integrity and efficiency in thermal management.
Implementation Method 1
The liquid cooling circuit is in thermal contact with the battery module
Implementation Method 2
The coupling member and the side wall of the carrier plate respectively include corresponding coupling elements mechanically connecting the coupling member and the carrier plate to each other
Data Source
AI summary
A battery pack for a vehicle includes: a battery module including a plurality of secondary battery cells; a carrier plate including an integral cooling channel structure having an opening at a side wall of the carrier plate; a liquid cooling circuit in thermal contact with the battery module; and a coupling member. The battery module is on the carrier plate. The integral cooling channel structure is part of the liquid cooling circuit, and the liquid cooling circuit includes a coolant distributor that is in a fluid-tight connection with the integral cooling channel structure at the opening at the side wall. The coupling member and the side wall of the carrier plate respectively include corresponding coupling elements to mechanically connect the coupling member and the carrier plate to each other, and the coupling member further includes a mounting bracket attaching the coolant distributor to the coupling member.