Battery Coolant Bypass Housing to Prevent Overflow Faults
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Solution Overview
Problem
Existing temperature control systems for high-voltage energy stores in motor vehicles are complex and costly, posing safety risks due to the need for numerous components and potential fluid overflows during faults.
Innovation Solution
A temperature control device with integrated line elements, a bypass line, and a bypass valve in a common housing, allowing fluid to bypass the energy store, preventing overflow and ensuring safety through a preassembled structural unit with switchable valves and sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional temperature control system with separate line elements is used, then temperature control function is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines the feed line element and return line element into a single integrated line element that directly connects to the energy store. This merging reduces the number of components and connections, thereby reducing device complexity while maintaining or improving safety through fewer potential failure points.
Solution Approach 2:
The integrated line element serves multiple functions: it acts as both a feed line and a return line, and incorporates both the temperature control function and the overflow prevention function through its direct connection design. This multi-functionality reduces the need for separate components, simplifying the overall system.
2Ease of manufacture
If numerous components are used for temperature control, then temperature regulation efficiency is improved, but manufacturing cost and system complexity increase
Solution Approach 1:
By merging the feed line and return line into a single integrated component that directly connects to the energy store, the patent reduces the total number of parts that need to be manufactured and assembled. This simplification directly lowers manufacturing costs while reducing system complexity.
3Reliability
If traditional temperature control systems are used, then temperature control is achieved, but fluid overflow risk during faults increases
Solution Approach 1:
The patent extracts the overflow prevention function from separate safety components and integrates it directly into the line element design through direct connection to the energy store. This eliminates the intermediate connections where overflow could occur, directly addressing the harmful factor while maintaining reliability.
Solution Approach 2:
The direct connection design inherently provides overflow protection by eliminating the need for complex valve systems. The simplified path prevents fluid accumulation and overflow before faults can occur, providing inherent safety without additional components.
4Weight of moving object
If multiple separate line elements are used, then temperature control functionality is achieved, but weight of the system increases
Solution Approach 1:
By combining multiple separate line elements into a single integrated line element, the patent directly reduces the total weight of the temperature control system. The merged structure eliminates redundant materials and connections, achieving weight reduction while simplifying the overall system structure.
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 provides a simple, cost-effective, and safe temperature control system by preventing fluid overflow and ensuring safe operation, reducing complexity and weight, while maintaining efficient temperature regulation.
Implementation Method 1
a cooling circuit (50) which is flushed by a temperature control fluid, by way of which the energy store (2) can be cooled
Implementation Method 2
a heating heat-exchanger (40), by way of which, in particular directly, heat can be transferred to the energy store (2)
Data Source
AI summary
A temperature control device for temperature control of an electrical energy store for a motor vehicle includes a feed line element which is flushable by a temperature control fluid for the temperature control of the energy store, and which constitutes a first line element via which the temperature control fluid flowing in the feed line element can be admitted to the energy store, and includes a return line element which is flushable by the temperature control fluid, and which constitutes a second line element via which temperature control fluid flowing in the energy store can be evacuated from the energy store. The line elements are arranged in a housing which is common to the line elements, in which a housing bypass line element which is fluidically connected or connectable to the line elements is arranged, by way of which the energy store can be bypassed by the temperature control fluid.