Hybrid Battery Pack Structure for Cooling and Gas Discharge
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Solution Overview
Problem
Newly designed hybrid vehicles require a DC power source with higher voltage and current capabilities to support advanced components like electric air-conditioners and electric turbochargers, while also needing to reduce fuel consumption and emissions, posing challenges for battery pack design in terms of size, heat management, and efficiency.
Innovation Solution
A battery pack design featuring serially connected battery cells with a fan assembly and heat dissipation system, where the battery cells are secured by end plates and a bearing plate, and a gas discharging mechanism is integrated into the pack's structure to manage pressure and heat, allowing for compact and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the battery pack uses more battery cells to increase voltage and current output, then the power capability improves, but the volume and size increase
Solution Approach 1:
The battery pack is divided into multiple individual battery cells (13 cells shown) that can be independently arranged and connected in series. Each cell is a separate module that contributes to the overall voltage and current output, allowing the system to achieve high power capability through modular assembly rather than using a single large battery unit.
Solution Approach 2:
The battery cells are arranged in a compact nested configuration within the housing, with cells positioned in rows and columns that maximize space utilization. The end plates and bearing plate create a nested structure that holds multiple cells in a space-efficient manner, achieving high power output without proportionally increasing volume.
2Power
If the battery pack increases current output capability, then the power delivery improves, but heat generation increases
Solution Approach 1:
The heat management function is extracted as a separate system from the battery cells themselves. A dedicated cooling system with coolant channels is integrated into the housing structure, allowing heat to be actively removed from the battery cells through fluid circulation rather than relying on passive heat dissipation.
Solution Approach 2:
A cooling fluid acts as an intermediary medium between the battery cells and the external environment. The coolant absorbs heat from the battery cells through thermal conduction via the bearing plate and housing, then transports this heat away from the battery pack, effectively managing temperature rise during high current operation.
3Temperature
If the battery pack uses more cooling components to improve heat management, then the thermal control improves, but the volume increases
Solution Approach 1:
The cooling system is merged with the structural housing and bearing plate components rather than being added as separate external parts. The bearing plate itself incorporates coolant channels, and the housing serves dual purposes as both structural enclosure and thermal management system, eliminating the need for additional dedicated cooling components that would increase volume.
Solution Approach 2:
The housing and bearing plate structures perform multiple functions simultaneously: they provide mechanical support and containment for the battery cells while also serving as the cooling system through integrated coolant channels. This multi-functionality allows effective heat dissipation without adding separate cooling components that would increase the overall pack volume.
4Stability of the object's composition
If the battery pack uses end plates to secure battery cells, then the structural stability improves, but the device complexity increases
Solution Approach 1:
The end plates serve multiple functions: they mechanically secure the battery cells in position, provide structural support for the overall pack, and act as thermal management components with integrated coolant channels. The bearing plate similarly provides both mechanical support and cooling functions, reducing the need for separate components.
Solution Approach 2:
The structural support function and thermal management function are merged into the same components (end plates and bearing plate). These plates simultaneously hold the battery cells securely and conduct heat away through embedded coolant channels, reducing the total number of separate components needed in the system.
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 battery pack effectively supports the increased power demands of hybrid vehicles, achieving 15% fuel savings and reduced CO2 emissions, with a compact size and enhanced heat management, while the integrated gas discharging and end plate design prevent overheating and accommodate battery expansion, extending service life.
Implementation Method 1
a fan assembly and heat dissipation system
Implementation Method 2
heat dissipation system
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2F
AI summary
The present disclosure provides a battery pack for a hybrid vehicle. The battery pack includes: multiple battery cells, a housing, a first end plate, a second end plate, a bearing plate and an upper cover, wherein the housing is provided with a bottom portion and side walls extending from the periphery of the bottom portion and forming an upper portion opening; the housing is configured for accommodating the multiple battery cells and the two end plates, when the multiple battery cells are sequentially arranged and mounted into the housing, the first end plate and the second end plate are located at two end sides of the sequentially arranged multiple battery cells to laterally fix the multiple battery cells; the bearing plate is mounted above the top portions of the multiple battery cells; and the upper cover is mounted above the housing to cover the upper portion opening of the housing.