Coupling Member for Battery Pack Cooling Circuit
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Solution Overview
Problem
The assembly of battery packs for electric vehicles is complex due to the need for precise mechanical and fluid connections between cooling plates and coolant interfaces, which often require manual assembly, additional mechanical fixation elements, and can be prone to tolerance issues, making automation difficult and the connection susceptible to failure.
Innovation Solution
A battery pack design featuring a carrier plate with integral cooling channels and a coupling member that includes mounting brackets and self-locking clamp elements for secure mechanical and fluid connections, eliminating the need for additional fixation means like screws, ensuring durable and vibration-resistant attachment of the coolant distributor to the carrier plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical fixation elements like screws are used to connect coolant distributor to carrier plate, then the connection can be securely established, but the assembly process becomes complex and requires additional parts
Solution Approach 1:
The coupling member integrates both the mechanical connection function and the coolant distribution function into a single component. The coupling member includes mounting brackets that directly attach to the carrier plate and form the coolant distributor, eliminating the need for separate fixation elements like screws and reducing the number of parts while maintaining secure connection.
Solution Approach 2:
The coupling member serves multiple functions simultaneously: it provides mechanical attachment to the carrier plate through mounting brackets, forms the coolant distributor for fluid distribution, and creates sealed connections. This multi-functional design replaces traditional separate components (fixation elements, distributor body, seals) with a single integrated part.
2Manufacturing precision
If manual assembly methods are used for connecting cooling plates and coolant interfaces, then precise mechanical and fluid connections can be achieved, but automation becomes difficult and assembly time increases
Solution Approach 1:
The coupling member is designed as a separate, pre-fabricated component that can be independently manufactured with high precision using automated processes. This segmentation allows the coupling member to be produced with precise geometries for both mechanical attachment and fluid distribution, then assembled as a unit to the carrier plate, facilitating automated assembly while maintaining connection precision.
Solution Approach 2:
The coupling member is pre-assembled with integrated mounting brackets and coolant distributor features before installation. This preliminary preparation of the coupling member allows for precise features to be created in advance using automated manufacturing, and the pre-assembled unit can then be quickly installed to the carrier plate, enabling automation while ensuring precision.
3Duration of action of stationary object
If additional mechanical fixation elements are used to secure the coolant distributor, then the connection durability is improved, but the assembly process requires more steps and additional parts
Solution Approach 1:
The mounting brackets are integrated directly into the coupling member structure, combining the fixation function with the coolant distributor body. This eliminates the need for separate mechanical fixation elements and reduces the number of assembly steps, as the coupling member itself provides both structural support and fluid distribution functions in a single component.
4Reliability
If traditional connection methods are used between coolant distributor and carrier plate, then the connection can be established, but the connection is susceptible to vibration and mechanical loads
Solution Approach 1:
The coupling member integrates the mounting brackets and coolant distributor into a single rigid structure that is directly attached to the carrier plate. This integrated design creates a stiff, vibration-resistant connection that eliminates loose fittings and separate fixation elements, improving the connection's ability to withstand mechanical loads and vibrations while maintaining reliability.
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 process, enhances the durability and reliability of the cooling circuit connections, and ensures tightness under various conditions, reducing assembly effort and mechanical loads, thereby improving the overall thermal management system's performance and longevity.
Implementation Method 1
the coupling member and the side wall of the carrier plate include a pair of corresponding coupling elements configured for establishing a mechanical connection between the coupling member and the carrier plate
Implementation Method 2
the integral cooling channel structure is part of the cooling circuit and further includes a coolant distributer configured for tightly connection to the integral cooling channel structure at the opening
Data Source
Figure 1~2
Figure 3
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AI summary
The present invention provides a novel battery pack for a vehicle. The battery pack comprises: - a battery module including a plurality of secondary battery cells, - a carrier plate with a top surface configured for supporting the battery module, wherein the carrier plate includes an integral cooling channel structure, the integral cooling channel structure having at least one opening at a side wall of the carrier plate, - a liquid cooling circuit being in thermal contact with the battery module, wherein the integral cooling channel structure is part of the cooling circuit and further includes a coolant distributer configured for tightly connection to the integral cooling channel structure at the opening, and - a coupling member, wherein the coupling member and the side wall of the carrier plate include a pair of corresponding coupling elements configured for establishing a mechanical connection between the coupling member and the carrier plate, and wherein the coupling member further includes mounting brackets for attachment of the coolant distributor.