Multi-Layer Battery Pack Structure With Integrated Cold Plates
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Solution Overview
Problem
Current battery pack designs for heavy duty vehicles face challenges in optimizing energy density, thermal management, mechanical stability, and serviceability due to constraints on size, weight, and packaging, while also requiring efficient cooling and mounting systems to withstand vibration and shock.
Innovation Solution
A multi-layer battery pack structure with integrated cold plates and a box frame design that minimizes internal frame clearances and outer enclosure boundaries, incorporating a thermal hose assembly and support brackets for enhanced structural support and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple sub pack stack-up structure is used for heavy duty trucks, then power and energy requirements are met, but weight increases and space utilization decreases
Solution Approach 1:
The patent merges the structural support function and thermal management function into a single integrated cold plate assembly. The cold plate structures are directly mounted to the battery modules to provide both mechanical support and cooling, eliminating the need for separate support structures and reducing overall weight while maintaining power capability for heavy duty applications
2Power
If multiple sub pack stack-up structure is used for heavy duty trucks, then power and energy requirements are met, but space utilization decreases
Solution Approach 1:
The patent combines structural support brackets and thermal management cold plates into an integrated assembly that occupies minimal space. The cold plate structures are mounted directly to battery modules, eliminating gaps and optimizing space utilization while providing sufficient power capability for heavy duty vehicles
3Quantity of substance
If internal stacking of battery structures is used, then energy density is improved, but serviceability and maintenance difficulty increases
Solution Approach 1:
The patent segments the battery pack into modular sub-packs with standardized mounting interfaces. Each sub-pack can be independently accessed and serviced, allowing maintenance personnel to work on individual modules without disassembling the entire battery assembly, thus maintaining high energy density through compact stacking while preserving serviceability
4Temperature
If integrated cold plate assembly is used, then thermal management is improved, but structural complexity increases
Solution Approach 1:
The cold plate structures serve multiple functions simultaneously: they provide thermal management by cooling battery modules, provide mechanical support by being mounted to the battery structure, and serve as mounting surfaces for thermal hose assemblies. This multi-functionality reduces the need for separate components, thereby managing complexity while improving thermal management
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 increases energy storage capacity, improves thermal management, enhances mechanical stability, and facilitates serviceability by reducing weight and space utilization, while maintaining efficient cooling and mounting systems.
Implementation Method 1
A plurality of first cold plate structures are mounted directly to at least one of the first and second plurality of mounting flanges
Implementation Method 2
A thermal hose assembly is connected to each of the plurality of first cold plate structures
Data Source
AI summary
A vehicle battery pack assembly includes a plurality of sub pack assemblies, each sub pack including a box frame. An internal frame assembly is disposed within the box frame. The box frame includes a front wall, a rear wall and a pair of side walls, one of the front wall and the rear wall includes a first plurality of mounting flanges vertically spaced there along and the pair of sidewalls each include a second plurality of mounting flanges vertically spaced there along. The internal frame assembly includes a plurality of first cold plate structures mounted directly to at least one of the first and second plurality of mounting flanges. A thermal hose assembly is connected to each of the plurality of first cold plate structures and a plurality of battery modules are supported on the plurality of first cold plate structures.