Modular Battery Module Fluid Manifold for Easy 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, particularly due to the use of rigid main distribution lines that require dismantling when replacing modules, and are complicated by the integration of electrical busbars and cable installations.
Innovation Solution
A modular fluid distribution system using node elements with flexible branch line sections and connecting elements that allow for decoupled busbar assembly/disassembly, featuring flexible line elements like corrugated hoses for tolerance compensation and easy assembly, and using identical or interchangeable parts to reduce complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid main distribution lines are used in the fluid distribution system, then the system structure is stable and easy to manufacture, but the entire line system must be dismantled when replacing a module, increasing maintenance complexity and time
Solution Approach 1:
The fluid distribution system is divided into modular components: main distribution lines, branch line sections, and connecting elements. This segmentation allows individual modules to be replaced without dismantling the entire system, as the modular design enables easy disconnection and reconnection of specific sections.
Solution Approach 2:
The system incorporates flexible line elements that allow dynamic adjustment and movement. This flexibility enables the system to adapt during maintenance operations, allowing module replacement without requiring complete system dismantling while maintaining stable fluid distribution.
2Area of stationary object
If the fluid distribution system is integrated with busbar and cable installations, then the system is compact and space-efficient, but the installation and maintenance become more complicated
Solution Approach 1:
The fluid distribution system is designed as a separate modular entity from electrical components. This segmentation allows independent installation, maintenance, and replacement of fluid modules without affecting electrical busbar and cable installations, reducing overall system complexity.
Solution Approach 2:
The modular fluid distribution system with standardized connecting elements can serve multiple functions and be applied in different configurations. This universality allows the same modular components to be used across various battery module arrangements, simplifying installation procedures.
3Ease of repair
If a modular design with flexible line elements is used, then individual modules can be replaced without dismantling the entire system, but the system structure becomes more complex
Solution Approach 1:
The system is segmented into standardized modular components with uniform connecting elements. This segmentation enables easy module replacement while keeping the overall structure manageable through repetition of identical or interchangeable parts.
Solution Approach 2:
The modular design uses identical or interchangeable parts throughout the system. This homogeneity reduces the variety of components that need to be managed, simplified inventory, and eased assembly procedures, offsetting the increased modularity with standardization.
4Adaptability or versatility
If curved connecting elements are used to align branch line sections with fluid connections, then the system adapts to varying module orientations, but manufacturing precision requirements increase
Solution Approach 1:
The connecting elements are designed with specific curvature parameters that allow adaptation to different module orientations. By standardizing these curvature parameters across interchangeable parts, the system achieves orientation flexibility while maintaining manageable manufacturing precision requirements through parameter standardization.
Data Source
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AI summary
A fluid distribution system for a battery module arrangement with a number of battery modules is described, wherein the battery modules each have at least one first fluid connection (F1) and at least one second fluid connection (F2), comprising: a first main line element (6) from which at least one first branch line section (7.1) branches off, preferably at right angles; a second main line element (6') from which at least one second branch line section (7.1') branches off, preferably at right angles; a first connecting element (8.1) which is detachably connected or connectable to the branch line section (7.1) of the first main line element (6); a second connecting element (8.2) which is detachably connected or connectable to the branch line section (7.1') of the second main line element (6'); which first connecting element (8.1) has a first curvature to align the direction of the first branching pipe section (7.1) with the direction of the first fluid connection (F1); which second connecting element (8.2) has a second curvature to align the direction of the second branching pipe section (7.1') with the direction of the second fluid connection (F2).