Battery Housing Cooling Channel with Segmented Flow Elements
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Solution Overview
Problem
Existing battery module cooling systems face challenges in achieving precise positioning and adequate support during assembly due to unevenness and pressure loss issues caused by flow-disturbing elements and covering means, which affects the service life and temperature gradient consistency.
Innovation Solution
The design incorporates normal and supporting flow-disturbing elements that project from the cooling channel bottom, with supporting elements being higher to provide structural support and maintain low pressure losses, allowing for accurate positioning and assembly without excessive deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flow-disturbing elements are placed close to the covering means to maximize cooling channel area, then cooling efficiency is improved, but pressure loss in coolant flow increases
Solution Approach 1:
The flow-disturbing elements are segmented into two distinct types: normal elements and supporting elements. This segmentation allows the cooling channel to serve dual functions: maximizing cooling efficiency through flow disturbance while maintaining structural support and minimizing pressure loss at specific locations.
Solution Approach 2:
Different regions of the cooling channel are assigned different qualities through the two types of flow-disturbing elements. Normal elements provide flow disturbance for cooling efficiency, while supporting elements provide structural support and maintain larger gaps to reduce pressure loss. This local differentiation resolves the contradiction between cooling efficiency and pressure loss.
2Strength
If the covering means is welded to the battery housing to ensure structural integrity, then strength is improved, but surface evenness deteriorates
Solution Approach 1:
The covering means is functionally segmented into regions that contact supporting elements (for positioning and support) and regions that are welded to the battery housing (for structural integrity). This segmentation allows welding to be concentrated at specific locations rather than across the entire surface, preserving surface evenness in critical areas.
Solution Approach 2:
The supporting elements act as intermediaries between the covering means and the battery housing. They provide the necessary support and positioning functions, allowing the covering means to be welded at discrete locations rather than requiring extensive welding that would compromise surface evenness.
3Measurement precision
If supporting elements are made higher to improve support function, then positioning accuracy is improved, but pressure loss increases due to reduced flow gap
Solution Approach 1:
The supporting elements are strategically positioned at specific locations where support and positioning are critical, rather than being uniformly distributed. This local placement allows them to provide necessary positioning accuracy while minimizing their impact on the overall coolant flow and pressure loss.
Solution Approach 2:
The supporting elements provide more than minimal support height to ensure adequate positioning accuracy, but their limited number and strategic placement mean the excessive height does not proportionally increase pressure loss. The partial presence of high elements balances support function with flow considerations.
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 precise positioning and assembly of battery modules with minimal pressure loss, ensuring stable support and maintaining a consistent temperature gradient, thus enhancing the service life and manufacturing efficiency.
Implementation Method 1
Another part of the flow-disturbing elements is designed in the form of supporting elements, the supporting elements being designed to be higher in the height direction than the normal elements in order to support a covering means covering the cooling channel
Implementation Method 2
flow-disturbing elements for disturbing a coolant flow in the cooling channel, the flow-disturbing elements projecting in a height direction in a projection-like manner from the cooling channel bottom
Implementation Method 3
The coolant is usually directed through cooling channels in the battery module
Implementation Method 4
Battery cells heat up as a result of chemical conversion processes, especially when power is delivered and consumed quickly
Data Source
AI summary
A battery housing part (11) for a battery housing (10) of a battery module (30) for accommodating battery cells, having a cooling channel (12) with a cooling channel bottom (13), a cooling channel wall (14) for delimiting the cooling channel (12), and flow-disturbing elements (15) for disturbing a coolant flow in the cooling channel (12), the flow-disturbing elements (15) projecting in a height direction (21) in a projection-like manner from the cooling channel bottom (13), and a part of the flow-disturbing elements (15) being designed in the form of normal elements (15a) and another part of the flow-disturbing elements (15) being designed in the form of supporting elements (15b), the supporting elements (15b) being designed to be higher in the height direction (21) than the normal elements (15a) in order to support a covering means (19) covering the cooling channel (12).