Battery Pack Housing and Heat Sink Integration for Cell Cooling
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Solution Overview
Problem
Conventional battery modules and packs face challenges in effectively dissipating heat generated by multiple battery cells, leading to accelerated deterioration, reduced lifespan, and increased risk of explosion or ignition, particularly in high-temperature conditions.
Innovation Solution
A battery pack design featuring a collective fastening method for end plates, housing, and heat sink, with a U-shaped refrigerant pipe and thermal resin layer, forming an integrated cooling structure that enhances heat dissipation through direct refrigerant contact and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are stacked to form a battery module, then capacity and output are enhanced, but heat dissipation becomes difficult and temperature increases rapidly
Solution Approach 1:
The housing bottom portion is merged with the heat sink to form an integrated cooling structure. The housing simultaneously serves as a structural enclosure and a heat dissipation component, eliminating the need for separate heat sink structures and improving thermal management efficiency
Solution Approach 2:
A thermal resin layer is introduced as an intermediary between the battery cell stack and the housing bottom portion. This thermal interface material facilitates efficient heat transfer from the battery cells to the housing/heat sink structure while ensuring uniform thermal contact
2Ease of manufacture
If conventional separate mounting methods are used for end plates, housing, and heat sink, then assembly is complex and manufacturing costs increase, but structural integrity may be compromised
Solution Approach 1:
The mounting structures for end plates, housing, and heat sink are merged into a collective fastening system. Fastening members pass through aligned holes in all three components simultaneously, creating a unified assembly process that reduces complexity while ensuring secure structural integration
Solution Approach 2:
The housing bottom portion serves multiple functions simultaneously: it provides structural enclosure, acts as a heat sink for thermal management, and serves as a mounting surface for the cooling structure. This multi-functionality reduces the number of separate components needed
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
Improves cooling performance, reduces manufacturing costs, increases spatial utility, and enhances safety by efficiently removing heat from battery cells, thereby extending lifespan and reducing explosion risks.
Implementation Method 1
a heat sink positioned below a bottom portion of the housing, wherein the bottom portion of the housing forms an upper plate of the heat sink
Implementation Method 2
U-shaped refrigerant pipe and thermal resin layer, forming an integrated cooling structure that enhances heat dissipation through direct refrigerant contact
Data Source
AI summary
A battery pack including: a battery cell stack including a plurality of battery cells; a housing for the battery cell stack; a pair of end plates that cover the front and rear surfaces of the battery cell stack and are coupled to the housing; and a heat sink positioned below a bottom portion of the housing. The bottom portion of the housing forms an upper plate of the heat sink, and mounting and fixing structures of the pair of end plates, the housing, and the heat sink are formed in a collective fastening method.