Truck Battery Pack Venting and Thermal Cavity for Frame Integration
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Solution Overview
Problem
Integrating battery packs into electric vehicles, such as electric trucks, is challenging due to the large space and weight requirements of battery packs, which affect weight distribution, heat management, and accessibility for maintenance.
Innovation Solution
The development of battery modules with a monolithically cast enclosure featuring tapered side walls and a thermal portion with thermal walls, which form a thermal cavity for efficient heat management, and the integration of pressure-relief valves for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery packs are positioned above the frame, then weight distribution is improved, but the vehicle's center of mass is raised
Solution Approach 1:
The battery pack is divided into multiple modules that can be distributed across different locations within the vehicle frame, allowing weight to be segmented and placed in optimal positions for both weight distribution and center of mass management
Solution Approach 2:
The battery pack design transitions from a single large unit to a modular system that can be arranged in three-dimensional space around the frame, utilizing vertical and lateral dimensions to optimize both weight distribution and center of mass position
2Temperature
If battery packs are positioned below the frame, then center of mass position is improved, but road clearance is reduced and battery packs are exposed to damage
Solution Approach 1:
The battery system is segmented into modular units that can be positioned at different heights and locations around the frame, allowing some modules to be placed in protected positions while maintaining low center of mass
Solution Approach 2:
The frame structure itself serves as a protective barrier for the battery modules, and the modular design allows for strategic placement of critical components in locations that are naturally protected from road debris and damage while still achieving low center of mass positioning
3Volume of moving object
If battery packs are integrated into the frame, then space utilization is improved, but frame modifications are required
Solution Approach 1:
The battery system is designed as separate modular units that can be integrated into the frame without requiring complex frame modifications, as each module is a self-contained unit that can be installed independently
Solution Approach 2:
The frame structure is designed to serve dual purposes: maintaining structural integrity and providing mounting points for battery modules, eliminating the need for separate modifications by making the frame itself compatible with modular battery integration
4Adaptability or versatility
If battery packs are placed in harsh conditions, then vehicle operational capability is improved, but battery pack durability is reduced
Solution Approach 1:
The battery system is divided into modular units with individual protection enclosures, allowing each module to be independently protected from harsh conditions while maintaining overall system operational capability in diverse environments
Solution Approach 2:
Each battery module is equipped with protective enclosures and environmental controls that are built-in from the design stage, providing beforehand protection against harsh conditions such as temperature extremes, moisture, and vibrations, thereby maintaining both operational capability and durability
5Temperature
If battery packs are integrated around the frame, then heat management is improved, but cooling provision is challenging
Solution Approach 1:
The thermal management system is segmented into modular cooling units that correspond to each battery module, allowing heat to be managed locally at each module rather than requiring a complex centralized cooling system
Solution Approach 2:
The cooling approach transitions from external centralized cooling to integrated thermal management where cooling channels are incorporated within the module structures themselves, utilizing the three-dimensional space within and around each module for efficient 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 solution enables easier integration of battery packs into electric vehicles by optimizing space and weight distribution, improving heat management, and ensuring safety through pressure-relief mechanisms, while allowing for relatively easy access for maintenance.
Implementation Method 1
a thermal portion, positioned between the two enclosure portions. The thermal portion comprises two thermal walls, which are operable as the bottoms of the two enclosure portions and form a thermal cavity between these thermal walls
Data Source
AI summary
Described herein are battery packs and electric vehicles using these packs. In some examples, a battery pack comprises two portions/covers and a set of battery modules positioned within the enclosed cavity formed by these portions. A battery pack may comprise a set of pressure-relief valves positioned in and protruding through a wall of at least one portion. Each valve can be coaxial with a corresponding gap provided between two adjacent modules. The valve is configured to provide a fluid path (to the exterior of the battery pack) when the pressure inside the pack exceeds a set threshold. In some examples, the battery pack comprises an inlet tube fluidically coupled to the inlet port of each module and an outlet tube fluidically coupled to the outlet port of each module. A set of specially configured orifices or controllable valves is positioned on the fluid path through each module.