Battery Cooling Manifold Assembly for Uniform Cell Temperature
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Solution Overview
Problem
Existing electrical energy storage devices for vehicles face challenges in achieving efficient and cost-effective temperature control, particularly in managing thermal variations of storage cells.
Innovation Solution
The device incorporates a distribution element connected to separate temperature control elements through which a fluid medium flows, allowing for separate and efficient temperature control of storage cells, with features like connection pieces, through-flow openings, and a two-component plastic design to facilitate assembly and tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate temperature control elements are used for each storage cell, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The temperature control system is divided into multiple separate temperature control elements, with each element dedicated to a specific storage cell. This segmentation enables independent temperature control for each cell, achieving precise thermal management while maintaining system simplicity through modular design
Solution Approach 2:
A common distribution element serves multiple temperature control elements simultaneously, distributing temperature control medium to all individual control elements. This multi-functional component reduces overall system complexity by consolidating distribution functions while still enabling individualized temperature control for each storage cell
2Ease of manufacture
If connection pieces are inserted into the distribution element, then assembly ease is improved, but manufacturing precision requirements increase
Solution Approach 1:
The distribution element incorporates elastic deformable regions that can change their physical parameters (shape, volume) in response to insertion forces. This elasticity allows the distribution element to adapt to tolerance variations in connection pieces, maintaining secure connections without requiring extremely tight manufacturing tolerances
Solution Approach 2:
The distribution element includes elastic deformable regions with wall portions that can flex and deform elastically. These flexible regions accommodate dimensional variations in inserted connection pieces, providing tolerance compensation while maintaining structural integrity and fluid sealing
3Ease of manufacture
If a two-component plastic design is used for the distribution element, then manufacturing cost is reduced, but material selection complexity increases
Solution Approach 1:
The distribution element is constructed as a two-component plastic part, combining two different plastic materials with complementary properties. This composite structure provides both elastic deformable regions for tolerance compensation and rigid regions for structural support, achieving functional requirements through material composition rather than complex mechanical design
Solution Approach 2:
Different regions of the distribution element utilize different plastic materials optimized for their specific functions. Elastic deformable regions use softer, more compliant plastic for tolerance accommodation, while other regions use rigid plastic for structural integrity. This localized material optimization reduces overall manufacturing cost by eliminating the need for post-assembly operations
4Manufacturing precision
If the distribution element has elastic deformable regions, then tolerance compensation is improved, but structural strength may be reduced
Solution Approach 1:
The distribution element employs a heterogeneous structure where elastic deformable regions are strategically placed only where tolerance compensation is needed for connection piece insertion. Other regions maintain rigid, high-strength construction to provide overall structural support. This localized differentiation allows the element to simultaneously achieve tolerance compensation and maintain adequate structural strength
Solution Approach 2:
The two-component plastic design enables creation of elastic deformable regions with controlled compliance while maintaining overall structural integrity. The combination of different plastic materials provides both the flexibility needed for tolerance accommodation and the rigidity required for structural strength, resolving the trade-off between compliance and strength
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 enables efficient, cost-effective, and uniform temperature control of storage cells, ensuring robust assembly and maintaining thermal stability with minimal assembly time and material costs.
Implementation Method 1
a heat transfer is executed from the temperature control medium, via the temperature control elements, to the storage cells
Implementation Method 2
in the event that the temperature control medium assumes a lower temperature than the storage cells, the temperature control medium is, or functions as a coolant, by which the storage cells are cooled
Data Source
AI summary
An electrical energy storage device includes storage cells and a plurality of temperature control elements through which a temperature control medium flows and by which the temperature of the storage cells can be controlled. A distribution element is common to the temperature control elements and through which the temperature control medium flows and into which associated connection pieces of the temperature control elements are inserted so that the temperature control elements are fluidically connected to the distribution element. The distribution element has a distribution channel common to the temperature control elements and through which the temperature control medium flows. For each temperature control element, the distribution element comprises at least one through-flow opening through which the temperature control medium flows and into which the associated connection piece of the associated temperature control element is inserted, and the associated connection piece projects at least partially into the distribution channel.