EV Battery Pack Gap Prevention Pad Cooling
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Solution Overview
Problem
The existing battery packs for electric vehicles suffer from deteriorated cooling performance due to gaps formed between the battery cell modules and cooling plates, which are influenced by the shape of the battery cell modules, and also experience vibration transmission from the road surface during driving.
Innovation Solution
A battery pack design that includes a battery cell module, a cell module support unit, a cooling plate matching the shape of the module, and a gap prevention pad to prevent gaps between the cooling plate and the module, along with an air conditioning module and heat exchanger system to enhance cooling efficiency and reduce vibration impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling plates are disposed on the underside of battery cell modules to remove heat, then heat removal capability is improved, but gaps form between the cooling plates and battery cell modules due to deformation or shape irregularities, deteriorating cooling performance
Solution Approach 1:
The patent introduces a gap prevention pad made of elastic material between the cooling plate and battery cell module. This flexible element deforms to fill gaps caused by manufacturing tolerances or thermal expansion, ensuring continuous thermal contact between the cooling plate and battery module throughout operation
Solution Approach 2:
The gap prevention pad acts as an intermediary element between the cooling plate and battery cell module. It mediates the contact interface by compensating for dimensional variations and maintaining reliable thermal coupling, thus ensuring consistent heat transfer performance
2Productivity
If battery cell modules are tightly fixed to maximize space utilization, then productivity is improved, but vibrations from the road surface are transmitted to the battery pack, reducing reliability
Solution Approach 1:
The elastic gap prevention pad serves as a vibration isolation element that absorbs road surface vibrations while maintaining tight contact between battery modules. The elastic material dampens mechanical shocks, protecting the battery pack from vibration-induced damage during vehicle operation
Solution Approach 2:
The patent pre-installs the elastic gap prevention pad between battery modules and the cooling plate structure before assembly. This cushioning element is positioned in advance to absorb and mitigate vibrations from road surfaces, preventing direct transmission of mechanical shocks to the battery cells
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 ensures effective heat transfer without gaps, even with convex or concave-shaped battery cell modules, and reduces vibration transmission by using elastic gap prevention pads, thereby improving cooling performance and durability.
Implementation Method 1
cooling plates 20B, 30B and 40B are disposed on the underside of the respective battery cell modules 20A, 30A and 40A in order to remove heat generated from the battery cell modules 20A, 30A and 40A. The cooling plates 20B, 30B and 40B serve to cool the battery cell modules 20A, 30A and 40A upon receiving coolant through a coolant hose
Implementation Method 2
a gap prevention pad configured to prevent a gap from being formed between the cooling plate and the battery cell module when the battery cell module is fixed in the battery receiving region
Data Source
AI summary
Disclosed is a battery pack for an electric vehicle including a battery cell module, a battery receiving region in which a cell module support unit configured to support the battery cell module is provided, a cooling plate provided between the battery cell module and the cell module support unit, the cooling plate having a shape corresponding to a shape of the battery cell module, and a gap prevention pad configured to prevent a gap from being formed between the cooling plate and the battery cell module when the battery cell module is fixed in the battery receiving region, thereby preventing deterioration in cooling performance and durability.