Structural Cold Plate Monocoque for EV Motorcycle Weight Reduction
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Solution Overview
Problem
In electric motorcycles, the combination of a non-structural cold plate and a structural plate results in an inefficient use of material and weight, as the cold plate is not designed to bear external stresses, leading to redundant metal presence and increased weight.
Innovation Solution
A structural cold plate is integrated into the monocoque, serving both as a cooling component and a stress member, enhancing torsional rigidity and reducing weight by eliminating the need for additional structural elements, while maintaining cooling effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a non-structural cold plate and structural plate are used separately, then cooling function is provided, but weight and material usage increase
Solution Approach 1:
The patent combines the cold plate and structural plate into a single integrated component. The cold plate serves dual functions as both a cooling element and a structural member of the monocoque chassis, eliminating the need for separate structural plates in certain locations. This merging reduces overall weight and material usage while maintaining both cooling effectiveness and structural integrity.
Solution Approach 2:
The cold plate is designed to perform multiple functions simultaneously: it provides thermal management for battery packs and power electronics while also serving as a stressed member of the chassis system. This multi-functionality allows the same component to fulfill both cooling and structural support roles, reducing the total number of parts and overall vehicle weight.
2Temperature
If a non-structural cold plate is used, then cooling function is provided, but structural integrity requires additional plates
Solution Approach 1:
The cold plate is merged with the structural requirements of the monocoque chassis. By designing the cold plate to serve as a stressed member, the patent eliminates the need for separate structural plates in specific locations, as the cold plate itself provides the necessary structural support while maintaining its cooling function.
Solution Approach 2:
The cold plate is designed with multi-functionality, serving both as a thermal management component and as a structural element that contributes to the chassis integrity. This allows the same component to fulfill both cooling and structural support roles, eliminating the need for additional separate plates.
3Temperature
If separate cold plate and structural plate are used, then cooling and structure are provided, but device complexity increases
Solution Approach 1:
The patent merges the cold plate and structural plate into a single integrated component, reducing the total number of parts in the system. This integration simplifies the overall device complexity by eliminating the need for separate structural plates in locations where the cold plate can provide structural support.
Solution Approach 2:
By designing the cold plate with multi-functionality to serve both cooling and structural roles, the patent reduces device complexity. The same component fulfills multiple functions, decreasing the number of separate elements needed in the system and simplifying assembly and maintenance.
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 overall weight by approximately 4.6 kg, optimizes the center of mass, and allows for further weight reductions in other areas, while maintaining effective cooling performance.
Implementation Method 1
The heat flows through a thermal interface of the heat-generating component to the cold plate through conduction, and then through convection from the cold plate to the coolant, moving the heat outside the system.
Implementation Method 2
The heat flows through a thermal interface of the heat-generating component to the cold plate through conduction
Implementation Method 3
That heat is then dissipated through a radiator into ambient air.
Data Source
AI summary
Presented is a system for cooling components of an electric motor vehicle. It utilizes the cold plate, a large metal plate necessary for cooling the batteries and electronics, as a structural member. Instead of being passively contained, the cold plate is used to increase the torsional rigidity of the monocoque. The structural cold plate takes on shear stresses, unlike a passively-contained, non-structural cold plate. The use of the cold plate itself as a stress member negates the need for additional redundant features or structures in the monocoque to resist forces and prevent flexure. Thus the monocoque can be pared down and its weight minimized or larger component accommodated. Cold plates can be made in several ways, from different materials, of varying thickness and shapes.