Battery Gap Filler Film Rolls for Thermal Bridging and Tolerance Compensation
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Solution Overview
Problem
Existing battery systems for motor vehicles are large, heavy, and difficult to assemble, with limited suitability as gap fillers for thermal bridging in motor vehicle batteries due to their complex structure and small volume design.
Innovation Solution
A battery system utilizing film rolls made of heat-conducting materials, arranged between cell module housings and cooling systems, serving as gap fillers, which provide effective thermal conductivity and tolerance compensation with easy handling and low pressing forces, using elastic roll fillings and film coverings for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling plates and heat-conducting elements are used in battery systems, then thermal management is achieved, but the system becomes complex and difficult to assemble
Solution Approach 1:
The patent combines multiple functions into a single integrated gap filler component that simultaneously provides thermal conduction, gap filling, and tolerance compensation. This eliminates the need for separate cooling plates and heat-conducting elements, reducing assembly complexity while maintaining effective thermal management.
Solution Approach 2:
The gap filler is designed as a multi-functional element that performs thermal conduction, gap filling, and tolerance compensation all in one component. This universal approach simplifies the overall battery system structure and reduces the number of parts that need to be assembled.
2Power
If battery systems are designed for motor vehicles with high power requirements, then power output is improved, but weight increases significantly
Solution Approach 1:
The patent employs thin-film heat-conducting elements and flexible gap fillers that provide effective thermal management with minimal mass. These thin-film structures achieve the required thermal conductivity without the weight penalty of traditional bulky cooling plates, enabling high-power battery systems to remain lightweight.
3Adaptability or versatility
If battery systems accommodate variable filling and thermal bridging in free spaces, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent uses elastic and compressible gap filler materials that can dynamically adapt to varying free spaces and tolerances. These materials automatically adjust their shape and volume to fill gaps effectively without requiring complex adjustable mechanisms or multiple specialized components.
Solution Approach 2:
The gap filler employs materials with variable physical properties, including compressible foam structures and elastic elements, that change their density and shape in response to applied pressure. This allows the same component to effectively fill various gap sizes and maintain thermal contact under different assembly conditions.
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 results in a lightweight battery system with enhanced thermal management and simplified assembly, capable of handling varying volume changes in free spaces, while maintaining effective heat transfer independent of compression.
Implementation Method 1
each comprising at least one elastic roll filling (42) and a film wrapping (44) enveloping the at least one roll filling
Implementation Method 2
film rolls made of heat-conducting materials, arranged between cell module housings and cooling systems
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A battery system according to the invention for a motor vehicle is arranged in a battery system housing, in which at least one cell module (16) with a cell module housing and at least one cooling system (22) for the cell module (16) are further arranged. The battery system housing also contains at least one arrangement (38) serving as a gap filler (12) made up of a plurality of film rolls (40), which comprises at least one elastic roll filling (42) and a film covering (44) enclosing the at least one roll filling (42).