Vehicle Battery Pack Thermal Management via Segmented Case Design
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Solution Overview
Problem
Existing battery packs for vehicles face challenges in cooling and heat management, particularly at low speeds or when stationary, leading to potential battery deterioration and life shortening due to external heat exposure.
Innovation Solution
A battery pack design featuring a sealed inner metal case with an open external case and an air flow channel, incorporating a radiator that contacts the inner case but not the external case, along with vibration-absorbing spacers and foreign material blocking plates, to facilitate cooling at high speeds and minimize heat ingress at low speeds or when stationary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the battery pack uses an open structure to facilitate cooling at high speeds, then cooling efficiency is improved, but external heat can easily enter the battery pack when the vehicle travels at low speed or stops
Solution Approach 1:
The battery pack structure is divided into two separate cases: an inner case that is sealed to protect the battery module, and an external case that is open to facilitate air flow and cooling. This segmentation allows the inner case to maintain a protected environment while the external case enables efficient heat dissipation through natural convection and forced air flow.
Solution Approach 2:
A radiator is introduced as an intermediary component between the inner case and external case. The radiator contacts the inner case but not the external case, serving as a heat transfer medium that facilitates cooling while preventing direct contact between external air and the sealed battery housing.
2Reliability
If the inner case is sealed to protect the battery module, then protection and sealing are improved, but heat dissipation capability deteriorates
Solution Approach 1:
The battery pack is divided into a sealed inner case for protection and an open external case for heat dissipation. The inner case maintains a controlled environment for the battery module while the external case provides a pathway for air flow and thermal management.
Solution Approach 2:
The radiator acts as an intermediary that bridges the sealed inner case and the external cooling environment. It transfers heat from the battery module through the inner case wall to the external air flow without compromising the sealed structure of the inner case.
3Ease of manufacture
If the battery pack structure is simplified, then manufacturing cost is reduced, but vibration resistance and heat management capability deteriorate
Solution Approach 1:
The battery pack is divided into modular components including the inner case, external case, spacers, and radiator. This segmentation allows each component to be manufactured separately using simple processes and then assembled, maintaining manufacturing simplicity while enabling complex functions like vibration isolation and thermal management.
Solution Approach 2:
Vibration-absorbing spacers are introduced as intermediary elements between the inner case and external case. These spacers provide vibration isolation and shock absorption while maintaining the structural integrity and simplicity of the overall design.
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 cools the battery pack at high speeds and prevents heat transfer from the environment at low speeds or during prolonged exposure, thereby reducing battery deterioration and extending its lifespan.
Implementation Method 1
an air flow channel between an external surface of the inner case and an inner surface of the external case, the air flow channel connecting the first opening part and the second opening part
Implementation Method 2
The radiator may contact the inner case and may not contact the external case
Implementation Method 3
The radiator may include a heat sink plate on the external surface of the inner case; and a heat sink pin on the heat sink plate, the heat sink pin extending parallel to a flow direction of external air
Implementation Method 4
The spacer may be formed of a vibration absorbing material. The spacer may be formed of a rubber material having a low thermal conductivity and being capable of absorbing vibration
Data Source
AI summary
A battery pack for a vehicle, the battery pack including a sealed inner case accommodating a battery module; an open external case surrounding the inner case, the open external case including a first opening part having an open side and a second opening part having another open side; and an air flow channel between an external surface of the inner case and an inner surface of the external case, the air flow channel connecting the first opening part and the second opening part.