Integrated Cooling Plate for Structural Battery Pack
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Solution Overview
Problem
Current battery-powered vehicles face limitations in range and structural soundness due to inefficient cooling systems with multiple hose connections, leading to reliability issues and trapped air that affects coolant flow.
Innovation Solution
A structurally integrated propulsion battery system with a single liquid cooling plate positioned between upper and lower internal structural cross beams, coupled via bolts, providing enhanced structural support and efficient cooling for extended vehicle range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple cooling plates with multiple hose connections are used, then cooling coverage is improved, but system complexity and reliability deteriorate due to trapped air and inefficient coolant flow
Solution Approach 1:
The patent combines multiple cooling plates into a single integrated cooling plate that spans the entire battery pack width. This merging eliminates the multiple hose connections and trapped air problems while maintaining comprehensive cooling coverage through the plate's extended surface area and integrated coolant distribution channels.
Solution Approach 2:
The single cooling plate serves multiple functions simultaneously: it cools all battery cells across the entire pack width, acts as a structural support element, and provides a unified coolant distribution system. This multi-functionality replaces the need for multiple separate cooling plates and hose connections.
2Temperature
If multiple cooling plates with multiple hose connections are used, then cooling coverage is improved, but manufacturing cost and system mass increase
Solution Approach 1:
The patent merges multiple separate cooling plates into one unified cooling plate structure. This reduction in component count simplifies the overall system, reduces manufacturing complexity, and lowers both material and assembly costs while maintaining effective cooling coverage through the integrated plate design.
3Strength
If structurally integrated batteries are used, then structural performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the structural support functions with the battery tray into an integrated unit. The single cooling plate is incorporated directly into the battery pack structure, eliminating the need for separate structural beams and simplifying the manufacturing process while maintaining enhanced structural performance.
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 enhances structural performance, reduces mass and cost, and ensures maximum occupant comfort by optimizing battery placement and cooling efficiency, addressing the limitations of range and reliability in existing systems.
Implementation Method 1
at least one liquid cooling plate located between the upper internal structural cross beam and the lower internal structural cross beam
Data Source
AI summary
A method and device for improving a structurally integrated propulsion battery system with a battery, a tray for accommodating the battery, with lower and upper internal structural cross beams coupled to the tray, and a liquid cooling plate located between the upper internal structural cross beam and the lower internal structural cross beam.