Battery Pack Thermal Structure for Fast Charging and Low Weight
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Solution Overview
Problem
Existing battery technologies face challenges in achieving fast and efficient charging while maintaining structural strength and light weight, with inadequate thermal management and material efficiency.
Innovation Solution
A battery arrangement incorporating extruded profiles as thermal structural elements that serve both cooling/heating and fixation functions, integrating cooling channels for efficient heat transfer and reducing material usage, allowing for rapid charging without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate parts and materials are used for battery fixation and cooling, then the battery pack can be assembled, but the amount of components and material increases resulting in higher weight and cost
Solution Approach 1:
The patent combines fixation elements and cooling channels into a single integrated thermal structural element. The fixation elements are formed as protrusions extending from the thermal structural element, eliminating the need for separate fixation components. This merging reduces the number of parts and material usage while maintaining both structural support and thermal management functions.
Solution Approach 2:
The thermal structural element serves multiple functions simultaneously: it provides structural support for the battery pack, fixes the batteries in position through integrated fixation elements, and manages thermal conditions through embedded cooling channels. This multi-functionality reduces component count and overall weight while achieving the same technical effects as multiple separate components would provide.
2Productivity
If fast charging is implemented, then charging speed increases, but the battery may overheat
Solution Approach 1:
The cooling channels are pre-integrated into the thermal structural element before battery assembly. This preliminary integration ensures that cooling capability is already in place and optimized before fast charging begins, allowing immediate heat dissipation during high-rate charging without requiring additional response time or external cooling systems.
Solution Approach 2:
The thermal structural element acts as an intermediary between the batteries and the cooling fluid. It provides thermally conductive pathways through the fixation elements and structural body, mediating heat transfer from the batteries to the cooling fluid circulating in the channels. This intermediary structure enables efficient heat removal during fast charging while maintaining electrical isolation and mechanical support.
3Reliability
If multiple separate components are used for thermal management and fixation, then functional requirements are met, but material usage and production complexity increase
Solution Approach 1:
The patent merges thermal management channels and fixation structures into a single integrated thermal structural element. The cooling channels are formed within the structural element itself, and fixation elements are created as protrusions from the same component. This consolidation reduces device complexity by eliminating multiple separate parts while maintaining reliable thermal management through the integrated cooling pathways.
4Stability of the object's composition
If traditional battery fixation methods are used, then batteries are secured, but additional parts and materials are required increasing weight
Solution Approach 1:
The fixation elements are merged with the thermal structural element, creating a single component that provides both structural support and battery positioning. The protrusions extending from the thermal structural element directly engage with the batteries to secure them in place, eliminating the need for separate fixation components such as clips, brackets, or adhesives that would add weight.
Solution Approach 2:
The thermal structural element performs the dual function of thermal management and mechanical fixation. By making the fixation elements an integral part of the thermal structural element, the design achieves position stability for the batteries without requiring additional dedicated fixation components, thereby reducing overall weight while maintaining secure battery mounting.
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
Enables faster battery charging in 5-6 minutes with improved thermal management, reduced material and weight, and enhanced structural strength, facilitating efficient recycling and reuse.
Implementation Method 1
The thermal structural element has a combined ability to fixate the batteries in position and at the same time regulate temperature of the batteries by either cooling or heating the batteries via at least one of the end plates
Implementation Method 2
the through channel being configured to lead a thermal fluid medium through the thermal structural element
Data Source
AI summary
A battery arrangement (1) comprising a number of batteries (2), arranged next to each other forming a battery pack (6a) with a top surface (7) and an opposing bottom surface (8), wherein the battery arrangement (1) comprises at least one thermal structural element (9) arranged against a top surface (7) and/or a bottom surface (8) of the battery pack (6a) for cooling or heating the batteries (2) via a top end plate (3) and/or a bottom end plate (4) of the batteries via a first through channel (10) in the thermal structural element (9) being configured to lead a thermal fluid medium through the thermal structural element (9), wherein the battery arrangement (1) comprises a fixation element (36; 15, 30, 37) configured to fixate the position of each battery (2) with relation to the thermal structural element (9).