Composite EV Battery Cross-Beam With Integrated Cooling Channels
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Solution Overview
Problem
Metallic cross-beams in electric vehicle battery packs are heavy, adding significant mass and requiring electrical insulation, while also needing to conduct heat effectively.
Innovation Solution
A composite cross-beam comprising a carbon fiber composite base, reinforced polymeric exterior vertical wall members, and metal inserts forming cooling channels, which are non-conductive and provide structural support and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic cross-beams are used for supporting batteries, then structural strength and heat conduction are improved, but weight increases significantly and electrical insulation is required
Solution Approach 1:
The cross-beam uses a composite structure combining carbon fiber composite base (providing strength and light weight) with metal inserts (providing heat conduction). This composite approach resolves the contradiction by integrating materials with complementary properties to simultaneously achieve high strength and low weight.
Solution Approach 2:
The cross-beam is divided into functional segments: carbon fiber base structure for mechanical support and metal inserts for thermal management. This segmentation allows each component to optimize its specific function while working together as an integrated system.
2Temperature
If metallic cross-beams are used for heat conduction, then cooling efficiency is improved, but electrical insulation requirements increase device complexity
Solution Approach 1:
The composite design with carbon fiber base and metal inserts provides both thermal conduction pathways and electrical insulation inherently, eliminating the need for additional insulation layers and simplifying the overall system design.
3Weight of moving object
If carbon fiber composite base is used, then weight is reduced, but heat conduction capability decreases
Solution Approach 1:
Metal inserts are embedded within the carbon fiber composite base to create hybrid heat conduction pathways. The metal inserts provide high thermal conductivity while the carbon fiber matrix maintains the lightweight structure, achieving both weight reduction and effective heat dissipation.
4Temperature
If metal inserts are added for cooling channels, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
Metal inserts are placed within the carbon fiber composite base structure, with cooling channels formed inside the metal inserts. This nested arrangement integrates multiple functions (structural support, thermal conduction, and fluid flow channels) into a single integrated component, reducing the number of separate parts and simplifying assembly.
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 composite cross-beam offers reduced weight, eliminates the need for insulation, and enhances cooling efficiency, maintaining battery temperature within the desired range.
Implementation Method 1
metal inserts forming cooling channels... efficient heat dissipation
Implementation Method 2
circulation of cooling fluid
Data Source
AI summary
A beam for supporting a plurality of prismatic batteries in battery enclosure of an electric vehicle includes a base, having a lower elongate horizontal flange, and an upper elongate horizontal flange, narrower than the lower elongate horizontal flange, spaced above the lower elongate horizontal flange by a vertical web. A web member can be disposed on the upper elongate horizontal flange of the base, and includes first and second elongate exterior vertical wall members. At least two elongate inserts disposed between the vertical exterior wall members, and configured to at least in part form at least one longitudinally extending channel between them. The elongate inserts can be made of metal and the longitudinally extending channel provides a pathway for cooling fluid. A cap can engage the upper edges of the vertical wall members and enclose the metal inserts in the space between the first and second vertical wall members.