Modular Thermo-Structural Battery Pack With Integrated Cooling
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Solution Overview
Problem
Existing battery enclosures face challenges such as high manufacturing costs and complexity, thermal management inefficiencies, and safety risks due to coolant leaks, leading to thermal runaway, while failing to adapt to various design considerations and applications.
Innovation Solution
Integrated metal alloy frames with cast structures that combine structural and thermal features, modular battery packs with interchangeable sub-packs, and efficient thermal regulation, allowing for adaptable manufacturing and enhanced safety through active thermal management and fail-safe designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate cold plate and enclosure design is used, then thermal management is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the cold plate and enclosure into a single integrated component. The enclosure serves dual functions as both structural housing and thermal management device, eliminating the need for separate cold plate assembly and reducing manufacturing complexity
Solution Approach 2:
The enclosure is designed to perform multiple functions simultaneously: structural support, protection of battery cells, and thermal management through integrated coolant flow paths. This multi-functionality reduces the total number of components needed
2Ease of manufacture
If integrated enclosure with coolant flow paths is used, then manufacturing complexity is reduced, but thermal management effectiveness may be compromised
Solution Approach 1:
The enclosure incorporates localized coolant flow paths positioned strategically near heat-generating battery cell regions. The thermal management capability is concentrated where most needed, maintaining effectiveness while integrating into the enclosure structure
Solution Approach 2:
The integrated enclosure acts as an intermediary between the battery cells and the coolant system, providing direct thermal coupling through built-in flow paths without requiring separate thermal management components
3Weight of moving object
If lightweight metal alloys are used for enclosure, then weight is reduced, but manufacturing cost increases
Solution Approach 1:
By combining the enclosure and cold plate into one integrated component, the patent eliminates the need for separate manufacturing and assembly processes, reducing overall manufacturing cost despite using lightweight materials
Solution Approach 2:
The lightweight enclosure performs multiple functions (structural support and thermal management), reducing the total material and component requirements, which offsets the higher cost of lightweight alloys
4Adaptability or versatility
If modular sub-pack design is used, then adaptability to various applications is improved, but integration complexity increases
Solution Approach 1:
The battery system is divided into modular sub-packs that can be independently manufactured and then assembled into different configurations. Each sub-pack is a self-contained unit with integrated thermal management, simplifying the integration process
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 provides lightweight, cost-effective battery packs with improved thermal performance, safety, and adaptability, enabling efficient manufacturing and scalable capacity while minimizing downtime and integration complexity.
Implementation Method 1
a first thermally conductive adhesive covering at least a portion of the conductive interface and in contact with the first metal alloy enclosure, the first thermally conductive adhesive configured to conduct heat from the first conductive interface and the first set of battery cells to the first metal alloy enclosure
Data Source
AI summary
Thermally managed electric vehicle battery packs and systems comprising a battery sub-packs designed to mate and coupled together such that the sub-packs define a battery cell compartment comprising a first set of battery cells and a second set of battery cells. The sub-packs can comprise integrated coolant compartments, ancillary compartments, or both. The sub-packs can comprise casted metal alloy frames defining various components of the battery packs. The battery packs and systems can comprise a stackable architecture that facilitates, among other things, efficient manufacturing of packs that can be stacked together, and efficient thermal regulation and space utilization in products.