Battery Pack Interlocking Holder Design for Thermal Management
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Solution Overview
Problem
Existing battery packs face challenges in efficiently assembling and cooling multiple secondary batteries, leading to potential overheating and instability, particularly due to uneven resin hardening and lack of effective ventilation.
Innovation Solution
A battery pack design featuring interlocking holders with pins and concave/convex surfaces for secure battery placement, along with conductive plates for electrical connection, and integrated cooling holes to prevent overheating, ensuring stable assembly and efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple secondary batteries are assembled in a battery pack, then high output is achieved, but heat accumulation and overheating occur
Solution Approach 1:
The battery pack is divided into multiple modular battery units arranged in columns and rows, with each battery independently positioned in holder cavities. This segmentation allows for distributed heat generation and facilitates targeted cooling pathways through the holder structure, preventing concentrated heat accumulation while maintaining high total output capacity.
Solution Approach 2:
The holder structure acts as an intermediary thermal management component, incorporating cooling channels and heat dissipation pathways between the batteries and the external environment. This intermediary structure facilitates heat transfer from the battery surfaces to the cooling system, preventing direct heat accumulation on the batteries while maintaining their high output operation.
2Stability of the object's composition
If batteries are securely fixed in holders, then stability is improved, but assembly complexity increases
Solution Approach 1:
The holder structure combines multiple functions into a single integrated component: mechanical support for battery positioning, secure fixation through pin-concave surface interlocking, and thermal management through integrated cooling channels. This merging reduces the number of separate components needed, simplifying assembly while maintaining battery stability.
Solution Approach 2:
The pin and concave surface features are self-aligning and self-locking, automatically securing batteries in the correct positions without requiring additional fastening operations or complex adjustment mechanisms. The batteries themselves serve as alignment guides, inserting into the holder cavities and engaging the fixation features automatically, thereby reducing assembly complexity while ensuring stability.
3Temperature
If cooling channels are integrated into holders, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling system is segmented into modular channels integrated within each holder unit, with each channel serving a specific battery or group of batteries. This segmentation allows for standardized manufacturing of holder units with pre-formed cooling channels, reducing overall manufacturing complexity while maintaining effective heat dissipation across the entire battery pack.
Solution Approach 2:
The holder is manufactured as a composite structure combining thermally conductive materials with the holder base material, creating integrated cooling channels that are structurally sound and thermally efficient. This composite approach allows for the formation of complex cooling geometries during a single manufacturing process, reducing the need for post-processing and assembly steps while achieving superior heat dissipation.
Data Source
AI summary
A battery pack includes a plurality of batteries arranged in columns and rows, a first holder configured to accommodate upper parts of the batteries, a lateral surface of the first holder including first pins, and a second holder configured to accommodate lower parts of the batteries, a lateral surface of the second holder including consecutively arranged concave surfaces and convex surfaces, and the first pins of the first holder protruding toward the second holder and being combinable with the concave surfaces of the lateral surface of the second holder.