Plastic Battery Housing With Integrated Cooling Channels
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Solution Overview
Problem
Current battery pack designs for hybrid and electric vehicles face challenges in optimizing lifespan, driving range, and charging time due to temperature regulation issues, and are often bulky, costly, and difficult to maintain, with metal housings that are inflexible and prone to corrosion.
Innovation Solution
A battery unit with a plastic housing composed of two integrated half-shells for the battery cells, featuring a thermoplastic material with integrated heat transfer fluid circulation means, reducing the number of junction zones and enhancing thermal insulation and cost-effectiveness, while avoiding the need for external hoses and conduits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal housing with external hoses and conduits is used for heat transfer fluid circulation, then heat exchange efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The housing walls are designed to integrate the heat transfer fluid circulation channels directly within them, merging the housing structure with the thermal regulation system. This eliminates the need for separate external hoses and conduits, reducing construction complexity while maintaining heat exchange efficiency through direct thermal contact with battery cells.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides mechanical protection for battery cells, acts as a thermal management system through integrated fluid circulation channels, and serves as a structural component. This multi-functionality reduces the overall number of components needed in the battery pack.
2Strength
If metal housing is used for battery pack, then structural strength is improved, but thermal insulation and corrosion resistance deteriorate
Solution Approach 1:
The housing is constructed from composite materials combining polymer base material with reinforcing fibers (such as glass fibers or carbon fibers). This composite structure provides sufficient mechanical strength while simultaneously offering inherent corrosion resistance and improved thermal insulation properties compared to pure metal construction.
Solution Approach 2:
The housing walls are designed with varying local properties: thicker sections with enhanced reinforcement provide structural strength where needed, while the polymer-based material throughout provides uniform corrosion resistance and thermal insulation. The integrated fluid channels in the walls provide localized heat exchange capability.
3Ease of manufacture
If multiple separate components are assembled for battery housing, then manufacturing flexibility is improved, but manufacturing precision and reliability decrease
Solution Approach 1:
The heat transfer fluid circulation channels are integrated directly into the housing wall structure during the molding process, merging what would otherwise be separate components. This integration eliminates multiple assembly steps and watertight connections, improving reliability while the modular housing design (separable into upper and lower parts) maintains manufacturing flexibility.
Solution Approach 2:
The housing is designed as modular components (upper and lower housing parts) that can be manufactured separately and assembled, providing manufacturing flexibility. The integrated fluid channels within each housing part maintain reliability by eliminating the need for external hose connections between components.
4Device complexity
If integrated housing design is used, then device complexity is reduced, but adaptability for different placements deteriorates
Solution Approach 1:
The housing is designed as a universal, standalone unit with standardized mounting interfaces that can be adapted to different vehicle configurations and placement locations. The integrated fluid channels are configured to work with standard heat transfer fluid circulation systems, enhancing versatility while maintaining construction simplicity.
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
This design improves thermal insulation, reduces production costs, simplifies maintenance, and enhances the compactness and efficiency of temperature regulation, thereby extending battery life and improving vehicle performance.
Implementation Method 1
means 4, 5 for regulating the temperature of said cells or elements 2 by circulation of heat transfer fluid
Implementation Method 2
means 4, 5 for regulating the temperature of said cells or elements 2 by circulation of heat transfer fluid
Implementation Method 3
The casing 3 is thus made up of two parts 6 and 7 forming two half-shells... made of a rigid plastic material... makes it possible to achieve simultaneously (compared to metal casings) better thermal insulation
Data Source
Figure 1A
Figure 1B
Figure 1C
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.