Modular Battery Cooling Module With Flat Tubes and Spacer Strips
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Solution Overview
Problem
Existing cooling systems for electric and hybrid vehicle batteries are costly and inflexible in adapting to varying numbers and shapes of battery cells, requiring improvements for efficient thermal management.
Innovation Solution
A cooling module with flat tubes and spacer strips that can be easily adapted to different battery configurations, using connectors and line segments for coolant lines, and optionally incorporating corrugated or planar tubes and spacer strips to optimize thermal coupling and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional cooling systems are used for batteries, then thermal management function is provided, but manufacturing cost is high and adaptability to varying battery configurations is poor
Solution Approach 1:
The cooling module is divided into modular components: flat tubes for thermal contact, spacer strips for positioning, and connector-coupled line segments for coolant distribution. This segmentation allows the system to be configured flexibly for different battery arrangements while simplifying manufacturing and assembly of each individual component.
2Ease of manufacture
If cooling systems are designed for specific battery configurations, then thermal efficiency is optimized, but manufacturing cost increases and flexibility decreases
Solution Approach 1:
The flat tubes serve multiple functions: they provide thermal contact with batteries, act as structural elements for mounting, and define cooling channels. The spacer strips similarly provide both positioning and structural support. This multi-functionality reduces the need for specialized components for different battery configurations, lowering manufacturing costs while maintaining thermal management effectiveness.
3Adaptability or versatility
If flat tubes are used for all batteries, then uniform cooling is achieved, but cost increases when full cooling capacity is not needed
Solution Approach 1:
The cooling system allows dynamic configuration where flat tubes can be selectively installed or removed based on the specific cooling requirements of different battery packs. This enables the system to adapt its cooling capacity to match the actual thermal management needs, avoiding unnecessary manufacturing costs for unused cooling components.
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 cost-effective and adaptable cooling system that efficiently manages thermal requirements of batteries, reducing production costs and enhancing mechanical stability while maintaining thermal efficiency.
Implementation Method 1
Batteries of electric or hybrid vehicles must be cooled during operation with coolant, usually an aqueous liquid
Implementation Method 2
The flat tubes... are connected to the coolant supply line and the coolant discharge line... which run at right angles to the coolant supply line and the coolant discharge line
Data Source
AI summary
A cooling module for batteries of an electric or hybrid vehicle has a coolant supply line, a coolant discharge line, and a plurality of flat tubes arranged side by side, between which there is space for batteries to be cooled, each of the flat tubes being connected to the coolant supply line or the coolant discharge line. The flat tubes each carry connectors. The coolant supply line and the coolant discharge line are each assembled from a plurality of line segments connected by a connector of one of the flat tubes to one of the connectors of an adjacent flat tube. A spacer strip is arranged between adjacent flat tubes. The spacer strip delimits between itself and each of the two adjacent flat tubes spaces for batteries that are to be cooled.