Battery Module Coolant Distributor for Simpler Heat Sink Assembly
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Solution Overview
Problem
Existing high-voltage battery designs for electric vehicles face complexity and high costs due to individual connections of heat sinks to coolant supply and discharge lines, which complicates construction and assembly.
Innovation Solution
The use of one-part coolant distributors that connect directly to both heat sinks and coolant supply/discharge lines, with components made of plastic and plug-in connections for simplified assembly and sealing, allows for a cost-effective and straightforward integration of coolant systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat sinks are individually connected to coolant supply line and coolant discharge line, then cooling function is achieved, but device complexity and assembly complexity increase considerably
Solution Approach 1:
The patent combines the coolant supply connection and coolant discharge connection into a single integrated connection element that connects to both heat sinks simultaneously. This merging of multiple separate connections into one unified component reduces the overall number of connection points and simplifies the cooling system architecture while maintaining effective cooling of all heat sinks.
Solution Approach 2:
The connection element serves multiple functions: it acts as both a coolant supply connection and a coolant discharge connection, and simultaneously connects to multiple heat sinks. This multi-functional design eliminates the need for separate dedicated connections for each heat sink, thereby reducing device complexity while ensuring reliable cooling.
2Reliability
If heat sinks are individually connected to coolant supply line and coolant discharge line, then cooling function is achieved, but assembly complexity increases considerably
Solution Approach 1:
By merging multiple connection functions into a single connection element, the assembly process is simplified. Instead of individually connecting separate supply and discharge lines to each heat sink, the assembler only needs to connect the integrated element, significantly reducing assembly steps and complexity while maintaining cooling effectiveness.
Solution Approach 2:
The connection element is pre-configured with integrated supply and discharge connections before assembly. This preliminary preparation of the connection structure allows for simpler and faster assembly at the final installation stage, as the complex multi-connection architecture has already been resolved in a single pre-assembled component.
3Reliability
If multiple separate connections are used for heat sinks, then cooling function is ensured, but costs increase considerably
Solution Approach 1:
The integration of multiple connection functions into a single connection element reduces the total number of components that need to be manufactured and assembled. This consolidation leads to lower material costs, reduced manufacturing complexity, and lower assembly costs, while still ensuring that all heat sinks receive adequate cooling through the integrated connection system.
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 simplifies the assembly and construction of high-voltage batteries by reducing complexity and costs, ensuring efficient coolant flow and heat transfer while maintaining optimal sealing and tolerance compensation.
Implementation Method 1
coolant-carrying heat sinks (3) for cooling the battery modules (2)
Implementation Method 2
coolant passes from the respective heat sink into the coolant discharge line
Data Source
AI summary
A high-voltage battery having a plurality of battery modules, coolant-carrying heat sinks for cooling the battery modules, a coolant supply line for supplying the coolant to the heat sinks via supply connections and discharge connections for discharging the coolant from the heat sinks to a coolant discharge line. In this high-voltage battery, the supply connections and the discharge connections respectively form a coolant distributor. The respective coolant distributor is connected to the heat sinks of the respective battery module.