EV Battery Pack Cooling Air Suction Port Design
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Solution Overview
Problem
Existing battery pack cooling systems for electric vehicles risk introducing dust or water into the battery case, potentially causing short circuits or ground faults, and using filters increases component count and pressure loss, reducing airflow.
Innovation Solution
A battery pack design with a cooling air suction port positioned downstream and opposing the flow direction, featuring a projecting portion that rises above the suction port to disturb airflow and remove dust or water, and a hollow portion to evaporate water using a heat generating member, with a cranked cooling air introduction passage between the battery case and floor panel to enhance filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a filter is used to remove dust or water from cooling air, then the cleanliness of cooling air is improved, but the number of components increases and the pressure loss of cooling air increases
Solution Approach 1:
The harmful factors (dust and water) are extracted from the cooling air through the projecting portion that creates a water seal barrier, separating the clean cooling air path from the contaminated air path without requiring additional filter components
Solution Approach 2:
The projecting portion acts as an intermediary structure that creates a water seal barrier, mediating between the external environment and the battery case interior to prevent dust and water entry while maintaining airflow
2Object-affected harmful factors
If a filter is used to remove dust or water from cooling air, then the cleanliness of cooling air is improved, but the pressure loss of cooling air increases and the flow rate decreases
Solution Approach 1:
The filtering function is extracted from a separate filter component and integrated into the battery case structure itself through the projecting portion, eliminating the pressure loss associated with traditional filters while maintaining dust and water removal capability
Solution Approach 2:
The cooling air suction port and projecting portion structure serves its own filtering function without requiring external filter components, creating a self-sufficient system that prevents dust and water entry while maintaining airflow efficiency
3Productivity
If the cooling air suction port is positioned to face the flow direction for maximum airflow, then the flow rate of cooling air is improved, but dust or water can easily enter the battery case
Solution Approach 1:
The suction port is positioned asymmetrically at the downstream end facing opposite to the flow direction, creating an asymmetric airflow pattern that allows high flow rate while the projecting portion creates a water seal barrier that prevents dust and water entry
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
Effectively prevents dust and water from entering the battery case by ensuring full contact with the projecting portion, increasing filtration efficiency, and quickly evaporating any water to prevent battery wetting, while maintaining airflow and reducing component count.
Implementation Method 1
a battery case (24) that houses a plurality of batteries (42), a cooling air suction port (48a) that sucks cooling air into a cooling passage formed in an interior of the battery case (24), and a cooling air discharge port (49a) that discharges cooling air from the cooling passage, wherein the cooling air suction port (48a) is provided in the vicinity of an end part on the downstream side, in a direction of flow of cooling air, on an exterior of the battery case (24) so as to oppose the direction of flow, the battery case (24) comprises a projecting portion (39a) that rises on the upstream side in the direction of flow of the cooling air suction port (48a) so as to disturb the flow of cooling air
Implementation Method 2
the projecting portion is formed so as to be hollow, and a heat generating member is housed in an interior thereof
Data Source
AI summary
In a battery pack for an electric vehicle, since a cooling air suction port (48a) is provided in the vicinity of an end part, on the downstream side in a direction of flow of cooling air, of a battery case (24) so as to oppose the direction of flow, cooling air is in full contact with the battery case (24) before flowing into the cooling air suction port (48a), and dust or water contained in cooling air can be made to adhere to the battery case (24) and removed, thus preventing dust or water from entering the interior of the battery case (24). In particular, since the battery case (24) includes a projecting portion (39a) that rises on the upstream side in the direction of flow of the cooling air suction port (48a) and disturbs the flow of cooling air, and an upper end of the projecting portion (39a) is at a position higher than that of the cooling air suction port (48a), it is possible to reliably put cooling air in contact with the projecting portion (39a) of the battery case (24), thus enhancing the effect in removing dust or water.