Structural Battery Cooling Channels Within Torsion-Stiff EV Packs
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Solution Overview
Problem
Existing battery packs in electric vehicles face challenges in integrating a highly-efficient cooling system without compromising cell volume or structural integrity, leading to increased weight, volume, or compromised NVH performance.
Innovation Solution
A battery assembly with spaced-apart longitudinal profiles and transverse beams, incorporating cooling channels within brackets that are rigidly attached to the frame structure, providing a compact and torsionally stiff design with improved NVH performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cooling ducts are routed outside battery pack, then structural integrity is improved, but NVH performance deteriorates
Solution Approach 1:
The patent merges the cooling system with the battery pack structure by integrating cooling ducts inside the battery pack and connecting them to the front transverse beam through brackets. This integration eliminates the need for separate external cooling structures while maintaining structural integrity and improving NVH performance by shielding the cooling system within the battery pack's torsionally stiff structure.
2Ease of manufacture
If internal battery pack structure is simplified for easier cooling duct pass-through, then ease of manufacture is improved, but structural integrity deteriorates
Solution Approach 1:
The brackets serve multiple functions: they structurally connect the interconnecting members to the front transverse beam, providing torsional stiffness, and simultaneously serve as mounting structures for the cooling duct pass-through. This multi-functionality simplifies manufacturing by using existing structural components for dual purposes while maintaining battery pack strength.
3Volume of stationary object
If cooling system is integrated into battery pack, then volume efficiency is improved, but structural integrity deteriorates
Solution Approach 1:
The cooling ducts are nested within the battery pack structure, passing through the front transverse beam and connecting to battery modules internally. This nesting approach maximizes volume efficiency by utilizing the existing structural space while the brackets provide reinforced connection points that maintain structural integrity despite the integrated cooling system.
4Strength
If battery pack size is increased to compensate for weaker structure, then structural integrity is improved, but weight increases
Solution Approach 1:
The battery pack is segmented into modular components (battery modules, interconnecting members, brackets) that can be independently optimized. The brackets are specifically designed as reinforcement elements at critical connection points, allowing localized strengthening without increasing the overall battery pack volume or weight.
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 achieves a rigid and well-shielded cooling system that protects the cooling ducts from mechanical forces, maintaining structural integrity and reducing weight, while enhancing NVH performance without increasing the battery or vehicle footprint.
Implementation Method 1
each battery module including cooling channels extending it the length direction and having an inlet situated between a transverse end face of the module and the inner surface of the front transverse beam
Implementation Method 2
The interconnecting members are attached to an inner surface of the front transverse beam via a bracket
Implementation Method 3
It is an object of the disclosure to provide a compact and torsionally stiff battery pack with an efficient and well-shielded cooling system. It is again an object of the disclosure to provide a battery pack that gives a good NVH performance
Data Source
AI summary
A battery assembly for an electric vehicle includes two spaced-apart longitudinal profiles extending in a length direction L, interconnected to a front and a rear transverse beam. At least three beam shaped battery modules are interconnected along their longitudinal sides via a plate-shaped interconnecting member, and extend in the length direction, to be attached to an inner surface of the front transverse beam via a bracket. Each battery module is provided with cooling channels extending in the length direction L and having an inlet situated between a transverse end face of the module and the inner surface of the front transverse beam. A water inlet duct extends from an external side the front transverse beam in a central area situated between the brackets, for connecting to a coolant inlet of the central battery module.