Battery Module Vertical Coolant Connection for Compact EV Packs
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Solution Overview
Problem
High-voltage batteries for electric vehicles face challenges in compactness and installation space due to the design of coolant connections, which protrude laterally and require battery modules to be positioned far apart, reducing the vehicle's range.
Innovation Solution
The battery module incorporates an intermediate pressure plate with a passage opening for the coolant connection, allowing it to protrude from the top side of the cooling plate, enabling fluidic coupling with coolant lines, thus eliminating the need for lateral guidance and allowing modules to be positioned closer together, enhancing packing density and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the coolant connection protrudes laterally from the cooling plate, then the coolant can be fed and discharged, but the battery modules must be positioned at a certain distance from one another, increasing installation space
Solution Approach 1:
The coolant connection is repositioned from a lateral protrusion to a vertical protrusion through the intermediate pressure plate. Instead of extending in the horizontal direction (width direction), the coolant connection now extends in the vertical direction (stacking direction), allowing it to pass through the intermediate pressure plate from the bottom side to the top side of the cell stack. This dimensional change enables coolant lines to be guided along the top side of the battery module rather than requiring lateral clearance.
Solution Approach 2:
The intermediate pressure plate serves multiple functions: it provides mechanical support and compression for the battery cells, and simultaneously serves as a conduit structure for the coolant connection. By integrating the coolant connection pathway through the intermediate pressure plate, the component performs both structural and fluidic functions, eliminating the need for separate lateral clearance for coolant line guidance.
2Use of energy by moving object
If the coolant connection protrudes laterally from the cooling plate, then coolant flow is enabled, but the high-voltage battery requires more installation space, reducing vehicle range
Solution Approach 1:
The coolant connection pathway is reoriented from horizontal to vertical alignment. The coolant connection now protrudes in the stacking direction through the intermediate pressure plate, allowing coolant lines to be routed along the top side of the battery module in the width direction. This eliminates the need for extended length in the stacking direction that would be required for lateral coolant connection guidance.
3Area of stationary object
If battery modules are positioned closer together to reduce installation space, then packing density increases, but lateral coolant connection guidance becomes difficult
Solution Approach 1:
By moving the coolant connection to the vertical dimension through the intermediate pressure plate, the coolant lines can be guided along the top side of the battery module in the width direction. This allows battery modules to be positioned closely together in the width direction without interfering with coolant line routing, as the coolant connections are now accessible from the top rather than requiring lateral clearance.
Solution Approach 2:
The intermediate pressure plate acts as an intermediary structure that facilitates coolant line guidance. By providing passage openings through which the coolant connection protrudes, the intermediate pressure plate serves as a mediator between the cooling plate and the external coolant lines, enabling compact module arrangement while maintaining straightforward coolant line routing along the top side.
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 results in a more compact high-voltage battery with increased packing density, stabilizing the battery modules and improving the vehicle's range by reducing installation space requirements.
Implementation Method 1
a cooling plate which is arranged on a bottom side of the cell stack and has a coolant connection for feeding and/or discharging a coolant which is conducted in the cooling plate
Implementation Method 2
at least one intermediate pressure plate which is arranged between two battery cells within the cell stack and has at least one passage opening along the vertical direction, in which passage opening the coolant connection is arranged and is guided in the direction of a top side of the cell stack for fluidic coupling to at least one coolant line of the high-voltage battery
Implementation Method 3
two end pressure plates which are arranged at ends of the cell stack which are situated opposite one another in the stacking direction and are designed for exerting a contact pressure onto the battery cells
Data Source
AI summary
A battery module for a high-voltage battery of a motor vehicle includes a cell stack with a plurality of prismatic battery cells stacked along a stacking direction, two end pressure plates, which are arranged on ends of the cell stack that are opposite one another in the stacking direction, and a cooling plate with a coolant connection for feeding and/or discharging a coolant. The coolant connection is formed so as to project in a vertical direction oriented perpendicularly to the stacking direction. At least one intermediate pressure plate, which is arranged between two battery cells within the cell stack and which has at least one passage opening along the vertical direction, in which passage opening the coolant connection is arranged and is led in the direction of a top side of the cell stack fluidically couples with at least one coolant line of the high-voltage battery.