Modular Battery Coolant Manifold for Easier Module Replacement
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Solution Overview
Problem
Existing fluid distribution systems for battery modules in electromobility are complex, costly, and difficult to assemble and service, requiring disassembly of the entire system for module replacement due to rigid main distribution lines and integrated busbar installations.
Innovation Solution
A modular fluid distribution system with flexible node elements and connecting lines, featuring detachable and secure couplings, allows for two-way fluid distribution and compensates assembly tolerances and temperature-related changes, enabling cost-effective assembly and servicing by decoupling busbar mounting and using flexible corrugated hoses for connecting main line elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid main distribution lines are used to connect battery modules, then the fluid distribution system provides stable fluid connection, but the entire system must be disassembled when a module is replaced
Solution Approach 1:
The fluid distribution system is divided into modular components: main distribution lines, branch line portions, and connection elements. Each battery module can be disconnected by removing only its associated connection element, while other modules remain connected. This segmentation enables individual module replacement without system-wide disassembly.
Solution Approach 2:
The connection elements are designed to be detachable rather than fixed, allowing dynamic reconfiguration of the fluid distribution system. Connection elements can be quickly connected or disconnected from battery modules, providing flexibility for maintenance and replacement operations while maintaining stable fluid connections during normal operation.
2Manufacturing precision
If the fluid distribution system is designed as an integrated rigid structure, then manufacturing precision can be maintained, but assembly and servicing become difficult and costly
Solution Approach 1:
The system is segmented into standardized modular components (main distribution lines, branch line portions, connection elements) that can be manufactured independently with controlled precision requirements. This reduces overall assembly complexity while maintaining connection precision through standardized interfaces.
Solution Approach 2:
The connection elements serve multiple functions: they provide fluid distribution, accommodate positioning tolerances through their curvature design, and enable quick connection/disconnection. This multi-functionality reduces the number of separate components needed and simplifies both manufacturing and assembly processes.
3Stability of the object's composition
If traditional rigid fluid distribution systems are used, then structural stability is maintained, but production and servicing costs increase
Solution Approach 1:
By segmenting the fluid distribution system into independent modular components, the patent reduces overall system complexity. Each module can be serviced or replaced independently, lowering maintenance costs and simplifying production while maintaining structural stability through standardized connection interfaces.
Data Source
AI summary
A fluid distribution system for a battery module arrangement including battery modules, each having first and second fluid connectors. The fluid distribution system includes: a first main line element from which there branches off at least one first branch line portion; a second main line element from which there branches off at least one second branch line portion; a first connection element detachably connected to the branch line portion of the first main line element; a second connection element detachably connected to the branch line portion of the second main line element; the first connection element has a first curvature to match a routing direction of the first branch line portion to a routing direction of the first fluid connector; and the second connection element has a second curvature to match a routing direction of the second branch line portion to a routing direction of the second fluid connector.