Integrated Liquid Cooling Battery Assembly
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Solution Overview
Problem
Current liquid cooling solutions for cylindrical power battery assemblies in electric vehicles face challenges such as complex processing and installation, high production costs, insulation performance risks, strict design and precision requirements, and the risk of glue leakage, as well as the potential for thermal runaway and chain reactions during battery cell overheating.
Innovation Solution
A high-performance thermal management power battery assembly is designed with a battery cell fixing module, staggered battery cells, a thermal conduction module made of thermally conductive graphite, and an integrated liquid cooling module within the assembly supporting device, which reduces weight and production costs while ensuring mechanical strength and reliability, and uses UV glue for precise bonding and improved control over curing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If undulating pipe or straight pipe liquid cooling assembly is employed, then cooling function is provided, but processing and installation difficulty increases
Solution Approach 1:
The patent integrates the cooling water pipe directly into the assembly supporting device, merging the cooling function with the structural support function. This eliminates the need for separate undulating or straight pipes, significantly simplifying processing and installation while maintaining effective cooling of the battery cells.
Solution Approach 2:
The assembly supporting device is designed to serve multiple functions: it provides structural support for the battery cells and simultaneously serves as the cooling water pipe channel. This multi-functional design reduces the number of components and simplifies manufacturing compared to dedicated cooling pipe systems.
2Temperature
If undulating pipe or straight pipe liquid cooling assembly is employed, then cooling function is provided, but insulation performance reliability deteriorates
Solution Approach 1:
By integrating the cooling water pipe into the assembly supporting device, the patent eliminates multiple connection interfaces between separate components. This reduces potential insulation failure points and improves the reliability of thermal insulation performance while maintaining effective cooling.
3Temperature
If undulating pipe or straight pipe liquid cooling assembly is employed, then cooling function is provided, but processing cost increases
Solution Approach 1:
The integration of cooling water pipes into the assembly supporting device reduces the total number of parts that need to be manufactured, processed, and assembled. This significantly lowers processing costs while maintaining the cooling function, as evidenced by the simplified structure requiring fewer precision machining operations.
4Temperature
If glue filling and cooling water pipe assembly is employed, then cooling function is provided, but design and processing precision requirements increase
Solution Approach 1:
The patent eliminates the need for glue filling by integrating the cooling water pipe directly into the assembly supporting device. This removes the complex requirements for glue viscosity, density, and thermal conductivity, as well as eliminating the need for precise control of glue filling processes, while maintaining effective cooling.
5Temperature
If glue filling and cooling water pipe assembly is employed, then cooling function is provided, but production difficulty increases due to glue leakage risk
Solution Approach 1:
By integrating the cooling water pipe into the assembly supporting device, the patent completely eliminates the glue filling process. This removes the risk of glue leakage during production and significantly simplifies manufacturing operations, while the cooling function is maintained through the integrated pipe structure.
6Temperature
If conventional liquid cooling assembly is employed, then cooling function is provided, but thermal runaway isolation capability deteriorates
Solution Approach 1:
The patent incorporates isolation structures within the assembly supporting device that segment the battery cell compartments. These segmentation features physically isolate individual battery cells, preventing thermal runaway propagation to adjacent cells while maintaining the cooling function through the integrated water pipe 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 solution effectively manages thermal runaway by isolating battery cells and improving temperature uniformity, enhancing the reliability and safety of the battery system while reducing production costs and weight, and increasing the service life of battery cells.
Implementation Method 1
a thermal conduction module, which is in contact with the plurality of staggered battery cells and the assembly supporting device
Implementation Method 2
the principle of various liquid cooling assemblies is to circulate coolant in a pipeline, thereby taking away the heat generated by the batteries
Implementation Method 3
a liquid cooling module, which is integrated in the assembly supporting device
Data Source
AI summary
A thermal management power battery assembly and a battery pack having a plurality of the thermal management power battery assemblies connected in series. The battery assembly includes a plurality of staggered battery cells, a thermal conduction module, a liquid cooling module, and a battery cell fixing module for fixing the battery cells. The battery cell fixing module includes a battery cell position limiting device, and assembly supporting device located at two sides of the battery cell position limiting device; the liquid cooling module is integrated in the assembly supporting device; the thermal conduction module is simultaneously in contact with the battery cells and the assembly supporting device. The liquid cooling module is integrated with the assembly supporting device. The liquid cooling module is intergrated with the assembly supporting device.