Modular Battery Pack Structure for Cooling and Impact Resistance
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Solution Overview
Problem
Existing battery packs for light electric vehicles are not compact, impact-resistant, and modular, lacking efficient thermal management and structural stability.
Innovation Solution
A modular battery pack design featuring polycarbonate cell holders, metal plates, and thermally conductive components that provide structural strength, impact resistance, and efficient cooling through thermally conductive materials and cooling channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional battery pack designs are used, then manufacturing simplicity is maintained, but compactness, impact resistance, and thermal management efficiency deteriorate
Solution Approach 1:
The battery pack is divided into modular components including cell holders, plates, and housing sections that can be independently manufactured and assembled. This segmentation enables compact design while maintaining manufacturing simplicity through standardized modules.
Solution Approach 2:
The design combines polycarbonate cell holders with metal plates and thermally conductive materials to create a composite structure that achieves compactness and impact resistance without excessive complexity. Each material is selected for its specific properties and combined in a modular assembly.
2Strength
If adequate impact resistance is provided, then structural strength is improved, but device complexity increases
Solution Approach 1:
The cell holders are designed with integrated protective features and cushioning elements built into the polycarbonate structure before assembly. This approach provides impact resistance through the inherent properties of the materials and geometry rather than adding complex external protection systems.
Solution Approach 2:
The polycarbonate cell holders act as flexible yet strong protective shells that absorb and distribute impact forces. The modular housing structure provides additional protective layers without requiring complex reinforcement systems.
3Temperature
If efficient thermal management is implemented, then temperature control is improved, but device complexity increases
Solution Approach 1:
The thermally conductive materials and plate structures are designed to passively conduct heat away from battery cells without requiring active control systems. The thermal management function is built into the structural components themselves, eliminating the need for separate complex thermal control systems.
Solution Approach 2:
Thermally conductive materials are integrated into the cell holders and plate structures to provide heat dissipation pathways. This combines structural support and thermal management functions in the same components, reducing overall system complexity.
4Adaptability or versatility
If modular design with multiple components is used, then adaptability and thermal management are improved, but manufacturing complexity increases
Solution Approach 1:
The battery pack is segmented into standardized modular components including cell holders, plates, and housing sections. Each module is designed for independent manufacturing using common processes and materials, maintaining ease of manufacture while enabling flexible assembly configurations for different applications.
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 design ensures compactness, impact resistance, and efficient thermal management, enhancing the longevity and performance of battery cells in light electric vehicles.
Implementation Method 1
thermally conductive adhesive in contact with a battery cell and one of the first plate and the second plate
Implementation Method 2
cooling channels
Implementation Method 3
polycarbonate cell holders, and metal plates that provide structural strength and impact resistance
Implementation Method 4
metal plates, and thermally conductive components that provide structural strength, impact resistance, and efficient cooling
Data Source
AI summary
Provided is a modular battery pack having six sides comprises a plurality of battery cells, a first and second cell holder having openings or notches to receive the ends of the battery cells, an electrical outlet connected to the plurality of battery cells, two plates attached to the sides of the cell holders, and two side housings that together form four sides of the modular battery pack, while the two plates form a fifth and a sixth side of the battery pack.