Battery Module Comb-Shaped Thermal Conductor Wedging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules for motor vehicles face challenges with thermal regulation, protection of individual cells, and assembly complexity, particularly in high-power and long-range batteries, where overheating and failure of one cell can damage the entire block due to inadequate ventilation and material limitations.
Innovation Solution
A battery module design featuring a support body with a comb-shaped cross-section made of a good thermal conductor, such as aluminum, and mechanical wedging means to securely hold and separate battery cells, allowing for effective thermal regulation and protection without forced ventilation, and enabling easy adaptation to various sizes and power formats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery elements are tightly assembled in blocks with binding material, then space utilization is improved, but thermal regulation becomes problematic and overheating can damage the entire battery
Solution Approach 1:
The battery elements are arranged in modular racks with individual slots, dividing the battery into separable units. This segmentation allows each element to be independently accessed and replaced, while maintaining organized spatial arrangement for efficient space utilization.
Solution Approach 2:
Thermal management plates are introduced as intermediary components between battery elements and the housing. These plates conduct heat away from individual cells, serving as heat transfer mediators that enable effective thermal regulation without compromising the compact block structure.
2Strength
If binding material is used to assemble battery elements, then mechanical strength is improved, but durability in demanding climatic conditions becomes questionable
Solution Approach 1:
Chemical binding materials are replaced with a mechanical fastening system consisting of racks, slots, and wedging means. This mechanical system provides secure assembly through physical interlocking features that are not susceptible to degradation from temperature extremes, humidity, or chemical exposure.
Solution Approach 2:
The assembly system uses composite construction with rigid support bodies, flexible sealing elements, and friction-based wedging components. This combination of materials with different properties provides both mechanical strength and adaptability to climatic variations.
3Reliability
If a large number of separate holding parts are used to assemble battery elements, then individual element protection is improved, but device complexity increases
Solution Approach 1:
Multiple holding functions are merged into integrated rack structures that combine support, positioning, and securing features in single components. The rack-slot-wedging system provides comprehensive element protection through unified design rather than multiple separate parts.
Solution Approach 2:
The rack structure serves multiple functions simultaneously: it provides mechanical support, defines precise positioning slots, enables thermal management plate attachment, and facilitates modular assembly/disassembly. This multi-functionality reduces overall system complexity while maintaining protective capabilities.
4Reliability
If battery elements are held individually in separate housings, then element protection is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The system segments battery elements into replaceable modular units within a shared rack structure. Each element maintains individual protection through its own slot and wedging mechanism, while the common rack body provides economical mass production opportunities.
Solution Approach 2:
The design allows easy modification of battery configurations by changing the number and arrangement of racks and slots. This parameter-based adaptability enables the same basic structure to accommodate different battery sizes and power formats without requiring complete redesign, reducing manufacturing costs.
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 design provides improved thermal regulation, secure cell positioning, and protection against cell failure, maintaining high power density while simplifying construction and ensuring effective air circulation for efficient cooling and heat exchange.
Implementation Method 1
at least one support body made of a rigid and good thermal conductor material, in particular a metallic material such as aluminum or an alloy thereof
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electric battery module (1) comprising a plurality of individual accumulators (2) in the form of cylindrical cells arranged in parallel rows mounted in a container (3). A battery module (1) characterised in that the container (3) comprises: at least one support body (4) made of a rigid material that is a good heat conductor in the form of a profiled part with a comb-shaped cross-section forming elongate cavities configured to each loosely receive a row of battery cells (2), as well as at least first mechanical wedging means (8) blocking the movements of said cells (2) at least in the longitudinal direction of the cavity receiving them and separating said cells (2) from the two compartmentalisation walls (5) that define said recess.