Adjustable Thermal Mid-Beam for Battery Row Separation and Cooling
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Solution Overview
Problem
Existing battery assemblies face challenges in maximizing usable volume within the housing by balancing structural support and heat removal, as central walls with thick cross-sections reduce available space.
Innovation Solution
An adjustable thermal mid-beam member is introduced between battery cell rows, providing structural support and acting as a thermal pathway to dissipate heat, while minimizing the cross-sectional footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a central wall is used to separate battery cell rows, then structural support is provided, but usable volume in the housing is reduced due to thick cross section
Solution Approach 1:
The central wall is segmented into a modular structure consisting of a first wall portion and a second wall portion connected by a connecting portion. This segmentation allows each component to be optimized independently, reducing the overall cross-sectional footprint while maintaining structural support functionality.
Solution Approach 2:
The connecting portion extends in a direction substantially perpendicular to the first and second wall portions, creating a three-dimensional configuration. This dimensional approach allows the wall to achieve structural rigidity through spatial arrangement rather than increasing the cross-sectional area in the traditional plane, thereby preserving usable volume.
2Temperature
If a central wall with cooling mechanism is used, then heat removal is facilitated, but cross-sectional footprint is increased
Solution Approach 1:
The cooling mechanism is merged with the wall structure itself, integrating thermal management functionality into the separating wall. This integration eliminates the need for separate cooling components that would increase cross-sectional footprint, as the wall serves both structural and thermal management functions simultaneously.
Solution Approach 2:
The wall structure is designed to perform multiple functions: structural separation of battery cell rows, structural support for the housing, and heat removal through integrated cooling channels. This multi-functionality reduces the need for additional components that would increase the cross-sectional footprint.
3Productivity
If additional volume is created for battery components, then battery efficiency is enhanced, but structural support and heat removal capabilities may be compromised
Solution Approach 1:
The design changes the geometric parameters of the wall structure, specifically reducing the cross-sectional footprint while optimizing the thickness and configuration of wall portions. This parameter optimization allows increased usable volume for battery components while maintaining sufficient structural integrity and heat removal capability through the integrated cooling mechanism.
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
Enhances battery efficiency by optimizing space utilization and effective heat management without increasing the assembly's size, thereby supporting a larger number of cells or components.
Implementation Method 1
the passage is defined between the first intermediate portion and the second intermediate portion... providing structural support and thermal pathways for heat dissipation
Data Source
AI summary
A battery assembly includes a housing having a base wall, a first end wall, a first side wall, and a second side wall. A plurality of battery cells is arranged in the housing. The plurality of battery cells includes a first plurality of battery cells arranged in a first row and a second plurality of battery cells arranged in a second row. A mid-beam member is arranged between the first row and the second row. The mid-beam member includes a first mid-beam element and a second mid-beam element. The first mid-beam element includes a first end having a first flange. The second mid-beam element includes a first end portion having a second flange. The mid-beam member includes a passage defined between the first mid-beam element and the second mid-beam element.