Plastic Battery Housing With Integrated Coolant Channels
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Solution Overview
Problem
Current battery pack designs for hybrid and electric vehicles face challenges in optimizing lifespan and operating autonomy due to temperature regulation issues, are inflexible and difficult to maintain, and have high production costs and corrosion risks, especially with metal housings that fail to thermally and electrically insulate the battery pack.
Innovation Solution
A battery unit with a plastic housing consisting of a bottom tray and top cover assembled peripherally, incorporating means for distributing and circulating heat-transfer fluid structurally within the tray, reducing the number of connections and enhancing thermal insulation while allowing for better heat exchange and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal housing is used for battery pack, then structural strength is improved, but thermal insulation and electrical insulation deteriorate
Solution Approach 1:
The housing is made of composite material consisting of a plastic base material reinforced with glass fibers or carbon fibers. This composite structure provides both the required mechanical strength and the necessary thermal and electrical insulation properties, resolving the contradiction between strength and insulation.
2Device complexity
If heat-transfer fluid circulation means are incorporated in the housing body, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The heat-transfer fluid circulation means are integrated directly into the housing body as a unified structure. The channels and passages for fluid circulation are formed as part of the housing manufacturing process, eliminating the need for separate components and reducing overall device complexity while maintaining functional performance.
3Object-affected harmful factors
If plastic material is used for housing, then thermal and electrical insulation is improved, but structural strength deteriorates
Solution Approach 1:
The housing uses a composite material system where plastic provides the base matrix with inherent thermal and electrical insulation properties, while embedded glass fibers or carbon fibers provide the necessary structural reinforcement. This combination achieves both insulation and strength requirements simultaneously.
4Manufacturing precision
If numerous tight connections are required during production, then assembly precision is improved, but production time and cost increase
Solution Approach 1:
By integrating the heat-transfer fluid circulation means directly into the housing body during the housing manufacturing process, the invention eliminates the need for numerous separate connections and assemblies. This reduces both production time and cost while maintaining the necessary assembly precision through unified manufacturing.
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 improved thermal insulation, reduced production costs, and easier maintenance by minimizing connections and exposure of heat-transfer fluid components, while maintaining efficient temperature regulation and compactness, thus enhancing the battery pack's performance and lifespan.
Implementation Method 1
means for regulating the temperature of said cells or elements by circulation of heat-transfer fluid
Implementation Method 2
the housing is made of a plastic material... providing thermal insulation while allowing for better heat exchange
Data Source
AI summary
The invention relates to a battery unit (1), particularly for a hybrid and/or electric motor vehicle, comprising a plurality of cells that are physically and/or electrically regrouped into a plurality of modules, a housing receiving and surrounding said cells, and means for regulating the temperature of said cells by circulation of a heat-transfer fluid. Said battery unit (1) is characterised in that the housing is made of a plastic material and consists of a lower tray (6), with a bottom and side walls, and an upper cover (7), which are peripherally assembled, and in that at least the tray (6) comprises means (5) for distribution/collection and circulation of the heat-transfer fluid, said means being structurally built into the body of said tray (6), by being formed at least partially as one piece therewith.