EV Battery Module Sealing for Temperature Control Fluid Containment
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Solution Overview
Problem
Existing battery apparatuses for electric vehicles face challenges in ensuring a reliable and cost-effective seal against the escape of temperature control fluid, requiring complex and precise sealing systems that are labor-intensive and costly to manufacture and install.
Innovation Solution
A two-stage sealing system is implemented, comprising a primary sealing apparatus within the battery module housing and a secondary sealing apparatus within the envelope housing, where the secondary sealing apparatus provides an additional barrier to prevent fluid escape, reducing the complexity and cost of individual sealants and allowing for simpler assembly and reduced production demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex sealing system with multiple sealants is used at individual joints between battery cells and modules, then the seal against tempering fluid leakage is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple individual sealing functions into a single integrated gasket that seals all joints between battery cells and modules. This gasket with multiple sealing elements replaces the need for multiple separate sealants at different joints, thereby reducing device complexity while maintaining comprehensive sealing functionality against tempering fluid leakage.
Solution Approach 2:
The integrated gasket serves multiple sealing functions simultaneously - it seals joints between adjacent battery cells, joints between battery modules, and joints between the housing and the battery assembly. This multi-functional component eliminates the need for different sealants at different locations, reducing both complexity and manufacturing cost while ensuring reliable sealing throughout the entire assembly.
2Reliability
If high precision manufacturing is required for housing components to meet tolerance accuracy requirements, then the sealing performance is improved, but the manufacturing cost and production time increase
Solution Approach 1:
The gasket with integrated sealing elements is specifically designed to compensate for tolerances in housing component manufacturing. By concentrating the sealing function in a dedicated component with built-in compliance features, the system allows housing components to be manufactured with relaxed tolerance requirements, thereby reducing manufacturing cost and production time while maintaining reliable sealing performance.
3Reliability
If extensive sealing measures are implemented at all joints, then the safety against tempering fluid escape is improved, but the installation effort and time increase
Solution Approach 1:
The integrated gasket combines multiple sealing functions into a single installable component. During assembly, this gasket is installed in one operation to seal all joints between battery cells, modules, and housing simultaneously. This approach maintains comprehensive safety against tempering fluid escape while dramatically reducing installation effort and time compared to applying multiple separate sealants at different joints.
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 two-stage sealing system significantly enhances safety against fluid leakage, allows for simpler and cheaper sealant production, and ensures continued efficient temperature control functionality even in case of primary sealing failure, by effectively containing any leakage within the envelope housing.
Implementation Method 1
the battery apparatus comprises at least one battery module with a plurality of individual battery cells. The battery module is also equipped with a module housing which is at least partially filled with temperature control fluid to control the temperature of the battery cells
Implementation Method 2
the module housing has a primary sealing apparatus to prevent the temperature control fluid from escaping from the module housing
Implementation Method 3
the battery module is accommodated in a module space of an envelope housing, which has a secondary sealing apparatus to prevent temperature control fluid from escaping from the envelope housing
Data Source
AI summary
A battery apparatus for an electrically driven vehicle, having at least one battery module including individual battery cells is provided. The battery module has a module housing, which, for the purpose of regulating the temperature of the battery cells, is at least partly filled with temperature-regulating liquid and has a primary sealing apparatus to prevent leakage of the temperature-regulating liquid from the module housing. The battery module is furthermore accommodated in a module space of an enveloping housing, which has a secondary sealing apparatus to prevent leakage of temperature-regulating liquid from the enveloping housing.