High-Voltage Battery Coolant Connection for Tolerance-Compensated Assembly
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Solution Overview
Problem
Existing high-voltage battery designs face challenges in assembly and welding due to the coolant connection hindering the process, particularly with rigid coolant lines that do not accommodate component tolerances.
Innovation Solution
A flexible coolant line with a two-part connection design, including a connection flange inside the battery and accessible threaded sleeves, allows for tolerance compensation and unhindered welding, combined with a flat seal for enhanced seal tightness and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid coolant connection is used, then the connection is structurally stable, but it hinders the assembly and welding of the battery cover due to component tolerances
Solution Approach 1:
The coolant connection is divided into two separate parts: a connection flange that is welded to the battery cover, and a coolant line that is connected to the flange. This segmentation allows the welding process to proceed without the coolant line interfering, while still providing a stable connected structure.
Solution Approach 2:
The coolant line is designed to be flexible rather than rigid, allowing it to adapt to component tolerances and misalignments. This dynamic flexibility enables easier assembly while maintaining a reliable connection, as the flexible line can compensate for variations in positioning.
2Ease of manufacture
If a flexible coolant line is used for tolerance compensation, then assembly ease is improved, but connection stability may be compromised
Solution Approach 1:
By separating the rigid connection flange (welded to cover) from the flexible coolant line, the design achieves both stability at the mounting point and flexibility in the connection, resolving the contradiction between assembly ease and connection reliability.
Solution Approach 2:
The coolant line is designed as a flexible component that can bend and adapt to tolerances, providing the necessary compliance for easy assembly while maintaining an secure fluid connection when engaged with the flange.
3Reliability
If the coolant connection is made accessible from outside for sealing, then seal tightness is improved, but device complexity increases
Solution Approach 1:
The connection is segmented into an internal flange for welding and an external interface for sealing. This allows the seal to be applied at the accessible external interface between the flange and coolant line, ensuring tightness without requiring complex internal sealing mechanisms.
Solution Approach 2:
The connection flange acts as an intermediary element between the battery cover and the coolant line. It provides a mounting surface for welding on one side and a sealing interface on the other, simplifying the overall structure by consolidating multiple functions into a single component.
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
Enables seamless assembly and welding of the battery cover by allowing flexible coolant line adjustments and secure sealing, ensuring effective coolant connection and battery integrity.
Implementation Method 1
a flexible coolant line with a two-part connection design, including a connection flange inside the battery and accessible threaded sleeves, allows for tolerance compensation
Implementation Method 2
The coolant connection can also comprise a flat seal for ensuring the seal tightness
Implementation Method 3
the coolant connection can comprise a connection flange with threaded sleeves that are accessible from outside of the high-voltage battery and that likewise contribute to ensuring the seal tightness and fixing the coolant connection
Data Source
AI summary
A high-voltage battery for a motor vehicle has a coolant connection of multipartite design. Also described is a corresponding method for producing the high-voltage battery, and a motor vehicle having a battery of this type.