Modular Battery Cooling Manifold for Independent Module Replacement
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Solution Overview
Problem
Existing fluid distribution systems for battery modules are complex, costly, and difficult to install and maintain, requiring disassembly of the entire system for module replacement due to rigid components and integrated busbar installations.
Innovation Solution
A modular fluid distribution system with flexible and detachable connections, using main and branch line elements with flexible sections and interchangeable connecting elements, allowing for tolerance compensation and independent module replacement without dismantling the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid components are used in the fluid distribution system, then structural stability is improved, but ease of installation and maintenance deteriorates
Solution Approach 1:
The fluid distribution system is divided into modular components: main distribution lines, branch line sections, and connecting elements. Each battery module can be connected to the fluid distribution system through detachable connecting elements, allowing individual module replacement without disassembling the entire system. This segmentation enables maintenance of individual components while maintaining overall structural stability.
Solution Approach 2:
The patent introduces flexible line sections that can be integrated into the otherwise rigid fluid distribution system. These flexible sections provide dynamic adaptability, allowing the system to accommodate movements and adjustments during installation and maintenance while maintaining structural integrity in operational state.
2Stability of the object's composition
If the entire piping system is assembled as an integrated unit, then system stability is improved, but ease of repair deteriorates
Solution Approach 1:
The system is segmented into independent battery modules that can be individually connected to the fluid distribution system through detachable connecting elements. This allows a single battery module to be replaced without disassembling the entire piping system, significantly improving ease of repair while maintaining system stability through the modular architecture.
Solution Approach 2:
The connecting elements are pre-configured with curvatures to align the direction of travel of branch line sections with the direction of fluid connections of battery modules. This preliminary alignment preparation simplifies the assembly and replacement process, making module replacement easier while maintaining a stable integrated system.
3Device complexity
If busbar installation is integrated with piping installation, then installation process is simplified, but adaptability deteriorates
Solution Approach 1:
The fluid distribution system is segmented into independent modular components that can be assembled and disconnected separately. This segmentation allows the fluid piping system to be handled independently from electrical busbars, providing adaptability in installation and maintenance operations while managing overall device complexity through standardized modular interfaces.
4Reliability
If complex fluid distribution systems are used, then cooling performance is improved, but manufacturing cost deteriorates
Solution Approach 1:
The patent develops universal connecting elements and branch line sections that can be used across multiple battery modules and configurations. The connecting elements with pre-configured curvatures serve multiple functions: alignment, connection, and adaptation to different module arrangements. This universality reduces the number of different components needed, simplifying manufacturing and reducing costs while maintaining effective cooling performance through proven fluid distribution architecture.
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
Facilitates cost-effective assembly and maintenance by enabling modular design, tolerance compensation, and independent module replacement, simplifying handling and reducing manufacturing costs.
Implementation Method 1
In order to provide the necessary tolerance compensation, in the fluid distribution system according to the invention a flexible line section of the respective main line element is arranged between a respective branch of the two first branch line sections and/or the two second branch line sections
Data Source
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AI summary
A fluid distribution system (4) for a battery module arrangement (1) with at least two battery modules (2.1-2.6) is described, wherein the battery modules (2.1-2.6) each have at least one first fluid connection (F1) and at least one second fluid connection (F2), and which fluid distribution system (4) comprises: a first main line element (6) from which at least two first branch line sections (7.1, 7.2) branch off, preferably at right angles; and a second main line element (6') from which at least two second branch line sections (7.1', 7.2') branch off, preferably at right angles; wherein each of the first branch line sections (7.1, 7.2) is detachably connected or connectable to a respective first connecting element (8.1, 8.2); and in which each of the second branch line sections (7.1', 7.2') is connected to a respective second connecting element (8.1, 8.2) is detachably connected or connectable; of which first connecting elements (8.1, 8.2) one has a first curvature and the other a second curvature in order to align the direction of each first branch line section (7.1, 7.2) with the direction of the first fluid connection (F1) of each of the battery modules (2.1-2.6); and of which second connecting elements (8.1, 8.2) one has a first curvature and the other a second curvature in order to align the direction of each second branch line section (7.1', 7.2') with the direction of the second fluid connection (F2) of each of the battery modules (2.1-2.6); wherein: the first connecting element (8.1) and the second connecting element (8.2) are connected or connectable to each other to form a jointly manageable unit; and/or the other first connecting element (8.2) and the other second connecting element (8.1) are connected or connectable to form a single, manageable unit.