Integrated Battery Pack Cooling Structure for Dense Module Assembly
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Solution Overview
Problem
Existing battery packs face inefficiencies in assembly processes and space utilization due to complex cooling structures and internal component arrangements, which hinder capacity and efficiency.
Innovation Solution
A battery pack design featuring a cooling-integrated large capacity battery module with a simplified structure, incorporating a heat sink, module frame, and refrigerant pipe assembly that enhances cooling efficiency and space utilization by integrating refrigerant pathways directly into the module frame, reducing unnecessary cooling structures and improving assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a complex cooling structure and intensive internal component arrangement are used, then cooling efficiency is improved, but assembly complexity increases and space utilization decreases
Solution Approach 1:
The cooling structure is merged with the battery module housing to form an integrated assembly. The housing serves dual functions as both structural enclosure and cooling channel carrier, eliminating separate cooling components and reducing assembly complexity while maintaining effective heat dissipation
2Temperature
If a complex cooling structure and intensive internal component arrangement are used, then cooling efficiency is improved, but space utilization decreases
Solution Approach 1:
The cooling channels are integrated into the battery module housing structure itself, allowing the housing to serve dual purposes as both protective enclosure and thermal management system. This eliminates wasted space from separate cooling components and maximizes space utilization while maintaining effective cooling
3Ease of manufacture
If conventional separate cooling structures are used, then assembly process is simplified, but cooling efficiency decreases
Solution Approach 1:
The cooling structure is merged with the battery module housing to form an integrated assembly. The housing serves dual functions as both structural enclosure and cooling channel carrier, eliminating separate cooling components and reducing assembly complexity while maintaining effective heat dissipation
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 simplifies internal components and structures, increasing capacity and space utilization by intensively arranging cooling structures with battery modules, enhancing cooling efficiency and reducing assembly complexity.
Implementation Method 1
a heat sink positioned under a bottom portion of the module frame
Implementation Method 2
a pack refrigerant pipe assembly connected to the battery modules
Implementation Method 3
a pack refrigerant pipe assembly connected to the battery modules
Implementation Method 4
pack refrigerant pipe assembly
Data Source
Figure 1
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AI summary
An embodiment of the present invention provides a battery pack including: a plurality of battery modules configured to include a battery cell stack in which a plurality of battery cells are stacked, a module frame accommodating the battery cell stack, and a heat sink positioned under a bottom portion of the module frame; a pack frame configured to accommodate the battery modules; a pack refrigerant pipe assembly connected to the battery modules; and a pack refrigerant pipe housing configured to accommodate the pack refrigerant pipe assembly. The battery modules include a first battery module and a second battery module facing each other, and the pack refrigerant pipe assembly and the pack refrigerant pipe housing are positioned between the first battery module and the second battery module.