Battery Module Thermal Flange for Even Load Distribution
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Solution Overview
Problem
Existing battery pack systems for electric vehicles face challenges in evenly distributing the weight of battery modules, leading to uneven strain on fasteners and inefficient thermal regulation, which can result in reduced structural efficiency and increased assembly complexity.
Innovation Solution
A thermal component with a flange is integrated into the battery pack system, positioned at the approximate center of gravity of the battery module, which includes a flange extension that supports the module's sides and is monolithically formed with the thermal component, reducing part count and assembly sequence, and facilitating even weight distribution and efficient thermal regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal components are added to regulate battery temperature, then thermal regulation efficiency is improved, but device complexity increases
Solution Approach 1:
The flange is integrated monolithically with the thermal component, combining two separate parts (flange and thermal component) into one unified structure. This reduces the total part count and eliminates the need for separate assembly steps, thereby reducing device complexity while maintaining effective thermal regulation functionality.
Solution Approach 2:
The thermal component with integrated flange serves multiple functions: it provides thermal regulation for the battery module and simultaneously acts as a structural mounting element that distributes weight and aligns the module. This multi-functionality reduces the need for additional separate components, thereby reducing device complexity while improving thermal regulation efficiency.
2Adaptability or versatility
If multiple separate components are used for mounting and thermal regulation, then adaptability is improved, but assembly complexity increases
Solution Approach 1:
The flange and thermal component are merged into a single monolithically formed part, reducing the number of assembly steps required. The integrated structure maintains the adaptability of having both mounting and thermal regulation functions while simplifying the assembly process by eliminating the need to separately assemble these components.
3Ease of manufacture
If weight is not evenly distributed, then manufacturing simplicity is improved, but structural efficiency deteriorates
Solution Approach 1:
The flange is positioned and designed to distribute the battery module's weight evenly across multiple fasteners, creating an equipotential load distribution. This ensures that each fastener experiences equal stress, optimizing structural efficiency and preventing premature failure, while the integrated monolithic design maintains manufacturing simplicity.
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 solution ensures even weight distribution across the battery module, reducing strain on fasteners and enhancing structural efficiency while providing efficient thermal regulation, thereby improving the overall performance and reliability of the battery pack system.
Implementation Method 1
The thermal component can couple with a lower, middle, or upper portion of a battery module... The thermal component and the flange can be monolithically formed to improve efficiency of manufacturing
Data Source
AI summary
An apparatus can include a thermal component that can couple with a battery module at a middle portion of the battery module. The thermal component can include a flange that extends from a side wall of the battery module. The flange of the thermal component can be disposed between a first tote flange of the battery module and a second tote flange of the battery module.