Embedded Exhaust Fan Layout for Air-Cooled EV Battery Packs
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Solution Overview
Problem
Conventional air-cooled battery packs face issues with fan noise, space utilization, and cooling performance due to the placement of exhaust fans outside the pack, which also increase costs.
Innovation Solution
An air-cooled battery pack design with exhaust fans embedded within the pack case, featuring inlet and outlet duct modules and cooling channels that optimize airflow and reduce fan noise, while using smaller fans for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If exhaust fans are placed outside the battery pack, then cooling performance can be maintained, but fan noise increases and space utilization deteriorates
Solution Approach 1:
The exhaust fan is merged with the battery pack structure by embedding it within the pack case. The fan housing is integrated into the pack case structure, and the fan assembly becomes a built-in component of the battery pack, combining the cooling function with the structural housing to eliminate external fan placement and reduce noise.
Solution Approach 2:
The exhaust fan is nested within the battery pack case structure. The fan housing is positioned inside the pack case, with the fan assembly nested within the available internal space, allowing the cooling system to be contained within the battery pack boundaries rather than requiring external placement.
2Ease of manufacture
If exhaust fans are placed outside the battery pack, then installation is simplified, but space utilization and layout design become difficult
Solution Approach 1:
The exhaust fan assembly is merged with the battery pack case as an integrated unit. The fan housing forms part of the pack case structure, and the fan is installed within the pack case boundaries, optimizing the use of internal space and simplifying the overall layout design within the vehicle.
Solution Approach 2:
The exhaust fan is repositioned from external placement to internal embedding within the three-dimensional space of the battery pack case. This dimensional reconfiguration allows the fan to utilize vertical and lateral space within the pack case that would otherwise be unused, improving space utilization without compromising installation feasibility.
3Temperature
If large exhaust fans are used for forced convection, then cooling performance is sufficient, but fan size increases and costs rise
Solution Approach 1:
The airflow path is optimized with locally configured inlet and outlet ducts that direct air flow efficiently through the battery pack. The duct modules create focused airflow channels that maximize the effectiveness of the smaller embedded fan, ensuring sufficient cooling performance without requiring large fan dimensions.
Solution Approach 2:
The system transitions from relying on large fan size to achieving cooling through optimized airflow parameters. The inlet and outlet duct modules create efficient flow paths, and the embedded fan operates at optimized speed and pressure parameters to deliver adequate forced convection with a compact size.
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 embedded fan design enhances space utilization, reduces fan noise, and maintains excellent cooling performance with economic efficiency.
Implementation Method 1
an exhaust fan embedded within the pack case and configured to forcedly exhaust air to outside of the pack case
Implementation Method 2
a cooling channel formed between the plurality of battery modules and a bottom surface of the pack case
Implementation Method 3
external air is introduced into the air-cooled battery pack 1 through the air inlet 2 to cool battery modules and is discharged to the outside through the air outlet 3
Data Source
AI summary
An air-cooled battery pack is provided, including a plurality of battery modules; a pack case including an air inlet and an air outlet and provided to accommodate the plurality of battery modules; a cooling channel formed between the plurality of battery modules and a bottom surface of the pack case; an inlet duct module configured to form an air passage from the air inlet to the cooling channel; and an outlet duct module including at least one exhaust fan installed within the pack case and provided to forcedly exhaust air to outside of the pack case by forming an air passage from the cooling channel to the air outlet.