Battery Pack Cooling Chamber and Resin Sealing Structure
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Solution Overview
Problem
Existing battery packs face challenges in efficiently dissipating heat and sealing cooling fluids, which can lead to reduced performance and reliability, especially in high-power applications like electric vehicles.
Innovation Solution
A battery pack design that incorporates a case with a cooling fluid accommodation space, where the fluid is in direct contact with battery cells, and a sealing structure using potting resin to prevent leakage, along with holder plates and a bus bar system for efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling fluid is used in direct contact with battery cells, then heat dissipation efficiency is improved, but risk of cooling fluid leakage increases
Solution Approach 1:
The battery pack is divided into separate functional zones: a cooling fluid accommodation space and a battery cell accommodation space. The holder plate acts as a physical separator between these zones, preventing direct contact between the cooling fluid and battery cells while maintaining thermal management efficiency through controlled heat transfer paths.
Solution Approach 2:
The holder plate serves as an intermediary structure between the cooling fluid and battery cells. It provides a sealed boundary that prevents cooling fluid leakage while allowing thermal energy to transfer from the battery cells to the cooling fluid through the plate material, thus maintaining both safety and heat dissipation performance.
2Volume of moving object
If holder plates are designed to accommodate both battery cells and cooling fluid, then space utilization is improved, but manufacturing precision requirements increase
Solution Approach 1:
The holder plate is designed with a specific height relationship to the battery cells and case, creating a standardized interface. The height of the holder plate is set to be equal to or greater than the height of the battery cells, ensuring that the cooling fluid accommodation space is properly defined without requiring complex tolerances. This standardized dimensional relationship simplifies manufacturing while achieving optimal space utilization.
3Reliability
If potting resin is used to seal the cooling fluid, then leakage prevention is improved, but manufacturing complexity increases
Solution Approach 1:
The holder plate and potting resin are combined into a unified sealing system. The holder plate provides the primary structural boundary, while the potting resin fills gaps and provides secondary sealing. This merging of mechanical and chemical sealing methods achieves reliable leakage prevention without requiring complex multi-step manufacturing processes, as both components can be integrated into a single assembly operation.
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 design enhances heat dissipation efficiency and ensures the cooling fluid does not leak, thereby improving the performance and reliability of the battery pack, particularly in high-power applications.
Implementation Method 1
a flow of a cooling fluid is induced for direct contact with battery cells, thereby improving heat dissipation efficiency
Data Source
AI summary
A battery pack includes: battery cells, each including end portions in a height direction thereof; a case accommodating the battery cells and a cooling fluid; and first and second holder plates coupled to the case to face each other along the case such that the end portions of the battery cells are insertable therethrough, an accommodation space being defined between the first and second holder plates to accommodate the cooling fluid, and the case, the battery cells, and the first and second holder plates have heights in the height direction that satisfy the condition: a height between the first and second holder plates<a height of the battery cells<a height of the case, and the battery pack further includes a potting resin on the first and second holder plates.