Battery Pack Riser Assembly for Dense Shipping and Coolant Coupling
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Solution Overview
Problem
Existing thermal management systems for traction battery packs in electrified vehicles face challenges in efficiently managing thermal energy while maintaining high packaging density during shipping and assembly.
Innovation Solution
A thermal management system featuring removably coupled risers and thermal exchange devices, with threaded connections and quick-connects, facilitates efficient coolant delivery and assembly, allowing uncoupled components to increase packaging density during shipping and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal management systems use integrated coolant delivery components, then thermal management efficiency is improved, but packaging density during shipping decreases
Solution Approach 1:
The thermal management system is divided into separate modular components: the thermal exchange device (with coolant ports) and the riser (with external threads). These segmented components can be shipped separately to maximize packaging density, then assembled through threaded engagement at the assembly plant, resolving the contradiction between integration for efficiency and segmentation for compact shipping.
2Ease of manufacture
If thermal management systems use permanently coupled components, then assembly simplicity is improved, but packaging density during shipping decreases
Solution Approach 1:
The connection between the thermal exchange device and riser transitions from a static permanent coupling to a dynamic removable coupling. The riser with external threads can be engaged with or disengaged from the coolant ports, allowing the system to adapt between shipped (disassembled) and assembled (connected) states, thereby achieving both compact packaging and simple assembly.
3Volume of moving object
If thermal management systems use removable riser connections, then packaging density during shipping is improved, but connection reliability may worsen
Solution Approach 1:
The riser is extracted as a separate removable component from the thermal exchange device, allowing it to be shipped independently to maximize packaging density. The riser features external threads that engage with the coolant ports, providing a reliable yet removable connection that can be easily assembled and disassembled without compromising connection integrity during operation.
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
Enhances thermal management efficiency and simplifies assembly by enabling uncoupled component transport, reducing packaging volume and improving assembly efficiency.
Implementation Method 1
a riser coupled to the thermal exchange device, the riser configured to fluidly couple the thermal exchange device to a coolant delivery system
Implementation Method 2
a thermal exchange device adjacent the at least one cell stack, the thermal exchange device having at least one coolant passageway that communicates a coolant
Data Source
AI summary
A thermal management system for a traction battery pack includes at least one cell stack having a plurality of battery cells, and a thermal exchange device adjacent the at least one cell stack. The thermal exchange device has at least one coolant passageway that communicates a coolant. A riser is coupled to the thermal exchange device. The riser is configured to fluidly couple the thermal exchange device to a coolant delivery system.