Battery Pack Cooling Structure With Stacked Plates and Side Pipe
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Solution Overview
Problem
Conventional battery packs face challenges with complex cooling structures and refrigerant leakage, which complicate assembly and pose risks of fire or explosion, while also having structural limitations in expanding capacity and cooling performance.
Innovation Solution
A battery pack design that integrates a two-stage battery module structure with vertically stacked cooling plates and a connecting cooling pipe, featuring a simplified cooling and mounting configuration, where the cooling pipe extends along one side of the module and includes mounting members and sealing members to enhance cooling efficiency and reduce part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cooling structure with separate cooling plates and mounting structures is used, then cooling performance can be achieved, but device complexity increases and assembly becomes complicated
Solution Approach 1:
The patent combines the cooling plate and mounting structure into a single integrated component. The cooling plate serves dual functions: providing thermal management for battery cells and serving as a mounting surface for securing the battery module to the pack frame. This integration eliminates separate mounting brackets or fasteners, reducing part count and assembly steps while maintaining effective cooling performance.
2Reliability
If multiple separate components are used for cooling and mounting, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
By integrating the cooling plate and mounting structure into one component, the patent reduces the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation typically reduces manufacturing costs through economies of scale, fewer tooling requirements, and simplified production processes while maintaining all necessary functional performance.
3Volume of moving object
If a compact battery module design is used, then space utilization improves, but heat dissipation becomes more difficult
Solution Approach 1:
The integrated cooling plate maintains direct thermal contact with battery cells while serving as a compact mounting structure. This design allows efficient heat transfer from cells to the cooling plate without requiring additional space for separate mounting components, thus maintaining compact form factor while ensuring effective heat dissipation.
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 integrated cooling and mounting structure simplifies assembly, improves cooling performance, reduces manufacturing costs, and enhances the rigidity and space utilization of the battery pack, while minimizing the risk of refrigerant leakage and explosion.
Implementation Method 1
a first cooling plate located below a bottom portion of the first module frame... a cooling pipe that connects the first cooling plate and the second cooling plate
Data Source
AI summary
A battery pack having a first battery module including a first battery cell stack in which a plurality of first battery cells are stacked, a first module frame for accommodating the first battery cell stack, and a first cooling plate located below a bottom portion of the first module frame, a second battery module including a second battery cell stack in which a plurality of second battery cells are stacked, a second module frame for accommodating the second battery cell stack, and a second cooling plate located below a bottom portion of the second module frame, a pack frame for accommodating the first and second battery modules, and a cooling pipe connecting the first cooling plate and the second cooling plate, the cooling pipe formed along one side part of the first battery module is provided. The first cooling plate and the second cooling plate are vertically stacked.