Structural Battery Cooling Channels for EV Pack Rigidity
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Solution Overview
Problem
Current battery electric vehicle (BEV) designs face challenges in integrating a highly-efficient cooling system without compromising cell volume or structural integrity, leading to compromised Noise, Vibration, and Harshness (NVH) performance or increased weight, as existing solutions either route cooling ducts outside the pack or result in a weaker internal structure.
Innovation Solution
A battery assembly with two spaced-apart longitudinal profiles interconnected to transverse beams, featuring beam-shaped battery modules with integrated cooling channels and a water inlet duct system that is rigidly attached to the front frame structure, providing a compact and torsionally stiff design with improved NVH properties and protected cooling manifold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling ducts are routed outside the battery pack, then the cooling system can be integrated, but the NVH performance is compromised
Solution Approach 1:
The cooling ducts are merged with the battery pack structure by routing them through the front transverse beam and integrating the cooling manifold within the battery pack's longitudinal profiles. This combines the cooling system with the structural framework, allowing efficient cooling while maintaining NVH performance through proper shielding and integration.
2Ease of manufacture
If a simpler internal battery pack structure is used to ease cooling duct pass-through, then cooling integration is improved, but the battery pack structural integrity is weakened
Solution Approach 1:
The battery pack is segmented into modular components with dedicated pathways for cooling ducts. The front transverse beam is designed with specific openings and the longitudinal profiles contain integrated manifolds, creating a segmented structure that facilitates cooling duct pass-through while maintaining overall structural integrity through the modular design.
3Strength
If the battery pack structure is strengthened to compensate for weakened sections, then structural integrity is improved, but the weight increases
Solution Approach 1:
The front transverse beam and longitudinal profiles serve multiple functions: they provide structural support for the battery pack while simultaneously housing the cooling ducts and manifolds. This multi-functionality eliminates the need for additional strengthening components, maintaining structural integrity without increasing weight.
4Temperature
If cooling manifolds are integrated within the battery pack, then cooling efficiency is improved, but the cell volume is reduced
Solution Approach 1:
The cooling manifolds are positioned in the transverse dimension within the front transverse beam and longitudinal profiles, rather than occupying longitudinal space that would reduce cell volume. This spatial arrangement in another dimension allows efficient cooling integration while preserving maximum cell volume for energy storage.
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 configuration enhances NVH performance, maintains structural integrity, and protects the cooling system from mechanical forces without increasing the battery or vehicle footprint, while ensuring efficient cooling and energy content.
Implementation Method 1
an active cooling system that involves cooling circuits in contact with the battery cells where a fluid is circulated
Implementation Method 2
cooling circuits in contact with the battery cells
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A battery assembly (9) for an electric vehicle comprises two spaced-apart longitudinal profiles (6,7) extending in a length direction L, interconnected to a front and a rear transverse beam (40,50). At least three beam shaped battery modules (15-18) are interconnected along their longitudinal sides (26-29) via a plate-shaped interconnecting member (35,36), and extend in the length direction, to be attached to an inner surface (42) of the front transverse beam (40) via a bracket (43,48). Each battery module (15-18) is provided with cooling channels (23,24) extending it the length direction L and having an inlet (55,56) situated between a transverse end face (59,60) of the module and the inner surface (42) of the front transverse beam (40). A water inlet duct (52,53) extends from an external side the front transverse beam (40) in a central area situated between the brackets (43,48), for connecting to a coolant inlet of the central battery module (16,17). Connecting areas on the external side of the front transverse beam (40) are provided for attaching to a front frame part (2,45,46) being situated adjacent to the central area, opposite the brackets (43,48), and a branching duct (54) extends between a front transverse side (60) of the central module (16,17) to an inlet (55,56) that is situated between the transverse end face (59) of the side modules (15,18) and the front transverse beam (40) via a channel (57,67) through the bracket (43,48).