Crossbeam-Embedded Battery Cooling for Compact EV Packs
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Solution Overview
Problem
Traditional air cooling technology is inadequate for highly integrated power battery assemblies in new energy vehicles, leading to inefficient thermal management and reduced energy density in battery packs.
Innovation Solution
A battery cooling system featuring a crossbeam with an avoidance groove that embeds a cooling assembly, including a collecting tube and cooling tubes, to efficiently cool battery modules without occupying excessive space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional air cooling technology is used, then the structure is simple, but the thermal management capability is insufficient for highly integrated power battery assemblies
Solution Approach 1:
The cooling assembly is nested within the avoidance groove of the crossbeam structure. The collecting tube and cooling tubes are integrated into the groove space, allowing the cooling system to be embedded within the existing structural framework rather than adding external components.
Solution Approach 2:
The cooling assembly is merged with the crossbeam structure by utilizing the avoidance groove. The cooling tubes are positioned within the groove and secured to the crossbeam, combining the structural support function with the thermal management function in a single integrated design.
2Reliability
If a liquid cooling system is added to improve thermal management, then the cooling performance increases, but the battery pack height and vehicle ground clearance are affected
Solution Approach 1:
The cooling assembly is arranged in the horizontal plane within the avoidance groove rather than extending vertically. The cooling tubes are positioned laterally within the groove space, transforming the cooling system from a vertical arrangement that increases pack height to a horizontal arrangement that maintains compact height while providing effective cooling.
Solution Approach 2:
The cooling assembly is nested within the avoidance groove of the crossbeam, utilizing the existing vertical space already allocated in the structure. This nesting approach allows the cooling system to be accommodated without increasing the overall battery pack height or affecting vehicle ground clearance.
3Reliability
If cooling tubes are added to cool battery modules, then thermal management improves, but the space for battery cells is reduced
Solution Approach 1:
The cooling assembly is nested within the avoidance groove, utilizing space that would otherwise be empty or structural. The cooling tubes are positioned within the groove space rather than occupying additional volume outside the structural framework, thereby maintaining maximum space for battery cells while providing effective cooling.
Solution Approach 2:
The cooling system is merged with the existing crossbeam structure, combining thermal management functionality with the structural framework. This integration allows the cooling tubes to be positioned within the structural groove rather than requiring separate dedicated cooling space, preserving battery cell volume while achieving effective cooling.
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 enhances thermal management, increases energy density, and optimizes vehicle interior space and ground clearance by reducing the height of the battery pack and allowing for more flexible vehicle design.
Implementation Method 1
the cooling assembly is configured to cool the battery module
Implementation Method 2
A battery cooling system... configured to cool the battery module
Data Source
AI summary
A battery cooling system provided by the present disclosure includes a crossbeam and a cooling assembly. The crossbeam defines an avoidance groove, the avoidance groove extends in a length direction of the crossbeam, and the avoidance groove is configured to mount the cooling assembly.