Resin-Encapsulated Battery Pack Cooling With Structural Support
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Solution Overview
Problem
Existing electric vehicle battery packs face challenges in efficient cooling and structural support, leading to potential temperature fluctuations and reduced battery life, as well as limitations in scalability and flexibility in power cell configuration.
Innovation Solution
A battery pack design featuring a housing with resin sheets for structural support and electrical insulation, a heat-absorbing fluid circulating through intervening spaces between power cells, and an integrated cooling system that allows for efficient heat management and scalability through modular configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power cells are arranged in parallel configuration with intervening spaces, then cooling efficiency is improved, but structural support and stability deteriorate
Solution Approach 1:
Resin encapsulation material is introduced as an intermediary substance that fills the intervening spaces between power cells. This resin serves dual functions: it maintains the cooling channels and fluid circulation paths while providing structural support and stability to the parallel-arranged power cells, thus resolving the contradiction between cooling efficiency and structural stability.
Solution Approach 2:
The patent employs composite material construction by combining power cells with resin encapsulation material. The resin-infused power cell assembly creates a composite structure where the resin matrix provides structural integrity while allowing fluid circulation channels to maintain cooling efficiency, thus achieving both structural support and effective cooling.
2Stability of the object's composition
If resin encapsulation is used to hold power cells in rigid configuration, then structural stability is improved, but heat dissipation may be hindered
Solution Approach 1:
The resin encapsulation is applied with local quality differentiation: it provides rigid structural support in regions requiring stability while maintaining open channels and spaces in regions requiring heat dissipation. The fluid circulation system is integrated within the resin structure to ensure heat dissipation pathways remain unobstructed, thus resolving the contradiction between structural stability and heat dissipation.
3Temperature
If power cells are arranged with intervening spaces for fluid circulation, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the resin encapsulation structure: it provides structural support, defines cooling channels, enables fluid circulation, and secures power cell positioning. By combining these functions into a single integrated resin structure rather than separate components, the design achieves efficient cooling while reducing overall device complexity.
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 enhances cooling efficiency, maintains stable temperatures, extends battery life, and allows for flexible power configurations and scalability, improving the overall performance and reliability of electric vehicle battery packs.
Implementation Method 1
a heat absorbing fluid within the housing, circulating through the intervening spaces contacting an exterior of at least one of the plurality of power cells
Implementation Method 2
heat absorbing fluid within the housing, circulating through the intervening spaces
Data Source
Figure 11A~11E
Figure 11F
Figure 12~13D
AI summary
An energy storage device for an electric vehicle comprising a housing (1105) defining an interior volume; a plurality of power cells (1200), arranged in the interior volume of the housing (1105), each power cell (1200) having a first terminal at one end and a second terminal at another end, each of the plurality of power cells (1200) extending in a substantially parallel configuration with intervening spaces being provided between adjacent power cells (1200); a resin sheet (1305, 1310) encapsulating at least one end of each of the plurality of power cells (1200) and holding the plurality of power cells (1200) in a rigid configuration; and a heat absorbing fluid within the housing (1105), circulating through the intervening spaces contacting an exterior of at least one of the plurality of power cells (1200).