Battery Module Locking Device Prevents Housing Bulging
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Solution Overview
Problem
Traction battery modules for electric or hybrid vehicles face issues with coolant bypass flows due to module housing bulging, leading to inadequate cooling and potential mechanical damage, and existing solutions like tie rods complicate assembly and are difficult to implement.
Innovation Solution
A locking device with form-fitting housing-side and stack-side locking points connects the battery cell stack directly to the module housing, enhancing stability and preventing bulging, allowing for efficient cooling and simplified assembly and disassembly without external access to locking points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the module housing is subjected to pump delivery pressure, then the coolant can be circulated through the battery cells, but large surfaces of the module housing bulge out causing unintentional bypass flows and inadequate cooling
Solution Approach 1:
The locking device is installed beforehand to prevent the bulging of the module housing before the coolant circulation causes the problem. By pre-applying counter-action (locking force) against the expected bulging pressure, the housing maintains its structural integrity and prevents bypass flows from forming during operation.
Solution Approach 2:
The locking device acts as an intermediary element between the module housing and the battery cell stack. It transfers and distributes the mechanical loads, allowing the housing to withstand pump delivery pressure without bulging while maintaining proper coolant flow paths through the battery cells.
2Stability of the object's composition
If tie rods are used to stiffen the module housing, then bulging is reduced, but assembly and disassembly become very involved due to accessibility requirements
Solution Approach 1:
Instead of using external tie rods that require accessibility for assembly, the locking device is integrated internally between the housing and battery cell stack. The locking points are positioned such that the battery cell stack itself serves as part of the locking mechanism, eliminating the need for externally accessible assembly points.
Solution Approach 2:
The locking device merges the structural support function with the mechanical connection function. By integrating the locking mechanism into the interface between the battery cell stack and module housing, it combines stiffening and securing functions into a single assembly process, reducing overall complexity.
3Strength
If multiple locking points are created between battery cell stack and module housing, then stability and stiffness increase, but the number of connection points increases complexity
Solution Approach 1:
The locking device is designed with universal applicability where the same basic locking mechanism can be replicated at multiple points. The housing-side locking points and stack-side locking points use standardized interfaces, allowing multiple connections to be made with consistent design patterns rather than unique solutions for each connection point.
Data Source
AI summary
A battery module for a traction battery may include a module housing through which a coolant is flowable and at least one battery cell stack arranged within an interior space of the module housing. The at least one battery cell stack may include a plurality of battery cells arranged one after another along a stack direction. The plurality of battery cells may be arranged within the module housing such that a coolant flowable through the module housing directly contacts the plurality of battery cells. A locking mechanism may form-fittingly connect the at least one battery cell stack to the module housing via (i) a plurality of housing-side locking points and (ii) a plurality of stack-side locking points.