Roll-Bonded Battery Pack Housing for Cooling and Impact Resistance
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Solution Overview
Problem
Existing battery packs face challenges in manufacturing costs, assembly complexity, and impact resistance due to the use of solid structures and extruded profiles, which require additional cooling plates and parts, leading to burdensome maintenance and increased weight.
Innovation Solution
A battery pack design utilizing roll-bonded metal sheets to form both cooling and crash channels within the housing, eliminating the need for separate parts by integrating these features directly into the structure through roll-bonding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid structures and extruded profiles are used for housing, then structural strength is improved, but device complexity and manufacturing cost increase due to additional cooling plates and parts
Solution Approach 1:
The housing structure is formed by roll-bonding multiple metal sheets together, merging the structural housing function with the cooling channel function into a single integrated component. The cooling channels are created by forming channels between the bonded metal sheets, eliminating the need for separate cooling plates and reducing overall device complexity while maintaining structural strength
Solution Approach 2:
The metal sheet housing structure serves multiple functions simultaneously: it provides structural enclosure, creates cooling channels through its layered construction, and offers crash protection. This multi-functionality reduces the number of separate components needed, simplifying the overall device while maintaining all necessary functions
2Temperature
If separate cooling plates and parts are used, then cooling function is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The cooling channels are integrated directly into the housing structure by forming channels between the roll-bonded metal sheets. This merging of cooling functionality into the existing housing structure eliminates the need for separate cooling plates, reducing manufacturing cost and assembly complexity while maintaining effective cooling function
Solution Approach 2:
The metal sheet housing structure simultaneously provides structural enclosure and thermal management functions through its layered construction with inter-sheet channels. This multi-functionality allows a single component to fulfill both structural and cooling roles, reducing the total number of parts and associated manufacturing and assembly costs
3Strength
If additional parts and structures are added for crash protection, then impact resistance is improved, but device complexity and weight increase
Solution Approach 1:
The metal sheet housing structure provides crash protection as an inherent function of its layered construction, rather than requiring separate crash protection components. The multiple bonded sheets create a structurally robust enclosure that resists impact forces, while the same structure simultaneously provides cooling channels and structural enclosure, reducing overall device complexity
4Ease of manufacture
If traditional housing with separate components is used, then assembly is simplified, but manufacturing cost and part quantity increase
Solution Approach 1:
Multiple metal sheets are roll-bonded together to form an integrated housing structure that combines structural enclosure, cooling channels, and crash protection into a single assembled component. This merging reduces the total number of separate parts that need to be handled during assembly, simplifying the assembly process while reducing manufacturing cost through integration
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 reduces manufacturing costs, simplifies assembly, enhances cooling efficiency, and improves impact resistance without additional components, providing a robust and efficient battery pack.
Implementation Method 1
a plurality of metal sheets which are roll-bonded to each other
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present disclosure refers to a battery pack (100). The battery pack (10) includes a plurality of battery cells (10) with a housing (20) including a bottom member (21), a plurality of side walls (22, 23, 24, 25) and a top member (30), wherein the bottom member (21), the plurality of side walls (22, 23, 24, 25) and the top member (30) form an interior accommodation space in which the plurality of battery cells (10) is accommodated. The battery pack (100) includes at least one among the plurality side walls (22, 23, 24, 25), the top member (30) and the bottom member (21) are formed by a plurality of metal sheets (41, 41', 41"; 42; 44, 44', 44") which are roll bonded to each other. Further, the battery pack (100) includes at least one cooling channel (40, 40', 40") is formed between bonding areas (43, 43', 43") of the plurality of metal sheets (41, 41', 41"; 42; 44, 44', 44"). In addition, the battery pack (100) includes at least one crash channel (45; 45'-1; 45'-2) is formed between bonding areas (43, 43', 43") of the plurality of the metal sheets (41, 41', 41"; 42; 44, 44', 44").