Battery Pack Fixing Bracket Structure for Leak-Safe Cooling
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Solution Overview
Problem
Conventional battery packs face issues with refrigerant leakage leading to potential fires or explosions, while also having complex cooling structures that are inefficient and prone to damage.
Innovation Solution
A battery pack design featuring a fixing bracket structure with protrusions and insulating members, integrated heat sinks, and sealed refrigerant passages to securely fasten battery modules and prevent refrigerant leakage, enhancing cooling efficiency and reducing component complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cooling system with separate mounting elements and cooling elements is used, then the battery module can be cooled, but the structure becomes complex and refrigerant leakage may occur
Solution Approach 1:
The patent combines the mounting bracket and cooling element into a single integrated component. The fixing bracket directly contacts the battery module to provide both mechanical support and thermal cooling, eliminating the need for separate mounting elements and cooling elements. This integration simplifies the overall structure while maintaining reliable refrigerant containment.
Solution Approach 2:
The fixing bracket serves multiple functions simultaneously: it provides mechanical mounting support for the battery module and acts as a cooling element through which refrigerant flows. This multi-functional design reduces the number of components needed while ensuring both structural integrity and effective cooling.
2Reliability
If multiple separate components are used for mounting and cooling, then the battery module can be securely fixed and cooled, but the number of components increases
Solution Approach 1:
The mounting bracket and cooling element are merged into a single integrated fixing bracket that performs both functions. The bracket is configured to directly contact the battery module for mechanical support while incorporating refrigerant flow passages for cooling, thereby reducing the total number of components.
Solution Approach 2:
The fixing bracket is designed with distinct functional zones: a mounting portion for mechanical attachment and a cooling portion with refrigerant passages. This segmentation within the integrated structure allows each function to be optimized while maintaining component unity.
3Temperature
If a complex cooling system with multiple elements is used, then cooling effectiveness can be maintained, but manufacturing complexity increases
Solution Approach 1:
By integrating the cooling element into the mounting bracket as a single component, the patent reduces manufacturing complexity. The combined structure can be manufactured as one piece or pre-assembled unit, simplifying production processes while maintaining effective cooling through properly designed refrigerant passages.
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 design effectively blocks refrigerant leakage, simplifies the structure, and improves cooling performance by integrating heat sinks and sealed passages, thereby increasing safety and reducing the risk of damage.
Implementation Method 1
a heat sink integrated with the module frame
Implementation Method 2
a refrigerant passage system that includes an inlet and outlet for direct cooling
Data Source
AI summary
An embodiment of the present invention provides a battery pack including: a plurality of battery modules each configured to include a battery cell stack on which a plurality of battery cells are stacked and a module frame for accommodating the battery cell stack; a pack frame configured to accommodate the battery modules; and fixing brackets respectively positioned on front and rear surfaces of the battery module, wherein protrusions are respectively formed on the front and rear surfaces of the battery module, and the fixing brackets surround the protrusions and are coupled to the pack frame.