Composite Pressing Element for Vehicle Battery Cooling
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Solution Overview
Problem
Existing cooling devices for automotive batteries are heavy, complex to mount, and suffer from reduced cooling efficiency due to metal components acting as heat bridges, necessitating a lightweight, easily manufactured, and effective cooling solution.
Innovation Solution
A composite cooling device with an elastic pressing element made from a separately manufactured metal reinforcing component enclosed in plastic material, which reduces weight and manufacturing costs while maintaining mechanical stability and long-lasting elastic properties, and features a low thermal conductivity to prevent heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal tension frame is used as a pressing element, then mechanical strength and stability are improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The pressing element is constructed as a composite component with a plastic housing and an integrated metal reinforcing component. This composite structure combines the low weight and corrosion resistance of plastic with the high strength and elasticity of metal, achieving both lightweight design and mechanical stability.
Solution Approach 2:
The metal reinforcing component is strategically positioned within the plastic housing only where structural strength and elastic pressing force are needed, rather than using metal throughout the entire pressing element. This localized reinforcement minimizes weight while maintaining necessary mechanical properties.
2Strength
If a metal tension frame is used as a pressing element, then mechanical strength is improved, but device complexity increases
Solution Approach 1:
The pressing element integrates multiple functions into a single composite component: the plastic housing provides structural form and mounting features, while the embedded metal reinforcing component provides elasticity and pressing force. This merging eliminates the need for separate mounting operations and simplifies installation.
Solution Approach 2:
The composite construction allows the pressing element to be manufactured as a unified component with integrated mounting features, reducing the number of parts and simplifying the mounting process compared to a traditional metal tension frame requiring multiple bolts and separate elements.
3Strength
If metal components are used in the cooling device, then mechanical strength is improved, but cooling efficiency decreases due to heat bridge effect
Solution Approach 1:
The harmful heat conduction function is extracted from the pressing element by using plastic as the primary material, which has low thermal conductivity. The metal reinforcing component is designed to provide only mechanical strength and elasticity while minimizing thermal transfer to the housing.
Solution Approach 2:
The composite structure combines plastic (low thermal conductivity) with metal (high strength), creating a pressing element that provides mechanical support while minimizing unwanted heat transfer. The plastic housing acts as thermal insulation, preventing the metal reinforcing component from creating a heat bridge to the external environment.
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 achieves a lightweight, efficient, and cost-effective cooling device with improved mechanical properties and extended lifespan, ensuring effective heat transfer and insulation, allowing for a compact design and easy assembly.
Implementation Method 1
The plastic material of the pressing element makes it possible to design the pressing element with a low thermal conductivity in particular. The plastic material enclosing the reinforcing component has a lower thermal conductivity than the reinforcing component in particular. This prevents unwanted transfer of heat with the cooling device.
Implementation Method 2
at least one separate pressing element, which is designed with elasticity, to press the coolant line against an exterior side
Data Source
AI summary
A cooling device for an automotive battery includes at least one coolant line and at least one separate pressing element which is designed to be elastic so as to press the coolant line against an exterior side, preferably a flat side, of the automotive battery. The pressing element is designed as a composite component which has a separately manufactured reinforcing component which is enclosed in a plastic material. A method for manufacturing the cooling device includes the acts of providing a reinforcing component, in particular an elastic metal component, manufacturing an elastic pressing element as a composite component by sheathing the reinforcing component with plastic material, and applying a coolant line to the composite component. The composite component is acted upon to press against the coolant line in the event of deformation perpendicular to the exterior side of the automotive battery to be cooled.