Battery Pack Junction Duct Noise Reduction
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Solution Overview
Problem
The existing battery pack designs generate noise due to turbulence caused by the cooling air from the fan, which is exacerbated by reinforcing members like vertical supports within the junction duct, obstructing airflow and leading to vibration and noise.
Innovation Solution
The battery pack incorporates a duct lower unit with a duct opening facing the fan opening and an upper case that forms part of the junction duct, eliminating the need for vertical supports and integrating the exhaust pipe with the duct lower unit, which reduces noise from turbulence and improves airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vertical supports are provided inside the junction duct to prevent deformation, then the structural strength of the junction duct is improved, but the cooling air flow is obstructed causing turbulence and noise generation
Solution Approach 1:
The invention removes the vertical supports from the junction duct to eliminate the source of turbulence and noise. The duct lower unit is designed without internal reinforcing members that would obstruct airflow, allowing cooling air to flow smoothly from the fan opening through the battery stack without causing vibration or noise.
Solution Approach 2:
The junction duct is constructed using a composite structure combining the duct lower unit made from blow-molded plastic with an integrated exhaust pipe. This composite design provides the necessary structural strength without requiring internal vertical supports that would obstruct airflow and generate noise.
2Stability of the object's composition
If vertical supports are provided inside the junction duct, then the junction duct rigidity is improved, but the cooling air path is obstructed causing vibration
Solution Approach 1:
The vertical supports are removed from the junction duct design to eliminate vibration caused by cooling air obstruction. The duct lower unit maintains its shape and rigidity through its blow-molded construction and integration with the exhaust pipe, without requiring internal vertical supports that would disrupt airflow and cause vibration.
3Strength
If the junction duct is designed with vertical supports, then the duct structural integrity is improved, but the overall device complexity increases
Solution Approach 1:
The vertical supports are eliminated from the junction duct design, simplifying the overall structure. The duct lower unit is designed as a simpler component that integrates directly with the exhaust pipe, reducing the number of parts and assembly steps while maintaining structural integrity through the blow-molded construction and integration approach.
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
This configuration reduces noise generation, enhances airflow efficiency, and increases the rigidity of the junction duct, allowing for a more compact design while maintaining effective cooling of the battery stack.
Implementation Method 1
a cooling fan for taking in cooling air from the outside for cooling the battery stack configured by combining multiple battery modules
Implementation Method 2
a junction duct for guiding the supply and exhaust of the medium between the fan opening and the battery stack
Data Source
AI summary
In a battery pack where a fan is housed within a case housing a battery stack, the noise generated from turbulence of a medium that is supplied and exhausted between a fan opening of the fan and the battery stack is reduced. The battery pack has a battery stack, a cooling fan installed adjacent to the battery stack and having a fan opening formed in a top surface for taking in cooling air after cooling the battery stack, an upper case for covering the upper part of the battery stack and the cooling fan, and a junction duct for guiding the cooling air after cooling the battery stack to the fan opening. The junction duct is formed from the duct lower unit having an opening formed at a location facing the fan opening and one wall of the upper case in contact with a lower end and periphery of the duct lower unit.