Battery Module Tray With Folded Corners and Cooling Channels
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Solution Overview
Problem
Existing trays for electrochemical storage modules in automotive applications face challenges in design complexity and manufacturing costs due to multiple panel assemblies at corners, leading to potential sealing defects and increased component count.
Innovation Solution
A tray design featuring a continuous lateral wall with folded corners and integrated heat-transfer fluid channels, made from assembled metal plates, which simplifies manufacturing and enhances sealing by reducing assembly points and optimizing heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple panels are assembled at corners to form lateral walls, then the structural flexibility and ease of assembly are improved, but sealing defects occur and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate corner panels into a single continuous lateral wall structure. This eliminates the corner joints that cause sealing defects while maintaining the ability to assemble the tray using standard joining methods along the continuous perimeter.
Solution Approach 2:
The lateral wall is segmented into standardized sections that can be manufactured separately and then joined using consistent joining lines. This segmentation approach maintains manufacturing flexibility while ensuring uniform sealing quality across all sections.
2Adaptability or versatility
If multiple panels are assembled at corners to form lateral walls, then the structural flexibility is improved, but the number of assembly points and manufacturing cost increase
Solution Approach 1:
The patent combines multiple corner panels into one continuous lateral wall, reducing the number of assembly points from multiple corner joints to standard perimeter joining lines only. This maintains structural flexibility while simplifying the assembly process.
Solution Approach 2:
The continuous lateral wall design creates a universal structure that can accommodate different tray configurations and sizes while using the same basic joining methodology, reducing the need for specialized corner assembly procedures.
3Reliability
If folded corners are implemented in continuous lateral walls, then sealing integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The folded corners are designed with rounded or curved geometries rather than sharp angles. This curvature distributes stress more evenly and is more tolerant of manufacturing variations, maintaining sealing integrity while reducing precision requirements.
Solution Approach 2:
The folding process utilizes controlled plastic deformation at specific temperature and pressure parameters to create permanent rounded corners. By optimizing these processing parameters, the design achieves both good sealing and tolerance to manufacturing variations.
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 design reduces manufacturing costs and improves sealing integrity while optimizing heat transfer efficiency for electrochemical modules, ensuring effective temperature regulation.
Implementation Method 1
at least one lateral wall fastened to the bottom wall and comprising, in particular, an internal plate and an external plate that are assembled together so as to form at least one heat-transfer fluid circulation channel
Implementation Method 2
heat-transfer fluid circulation channel
Data Source
AI summary
A tray is configured to accommodate a part capable of giving off heat during its operation. The part may be an electrochemical energy storage module. The tray includes a bottom wall configured to accommodate the part and at least one side wall attached to the bottom wall. The at least one lateral wall includes an internal plate and an external plate that are assembled together to form at least one heat transfer fluid flow channel. The side wall includes a periphery provided with at least one folded corner.