Cooler Block with Force Absorbing Plate for Vehicle Power Supply

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Solution Overview

Problem

Existing power supply devices for motor vehicles face challenges in protecting electrochemical storage cells and double layer capacitors from damage during accidents, particularly due to potential short circuits and thermal events, which can lead to environmental and safety hazards.

Innovation Solution

A device with a cooler block that incorporates a force-absorbing element, such as a plate-shaped crash plate, to divert forces away from storage cell modules during a crash, combined with a clamping device for enhanced heat dissipation and mechanical attachment, ensuring the storage cells and capacitors are protected from mechanical and thermal damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If storage cells and double layer capacitors are arranged in series and/or parallel to provide sufficient energy, then the energy output is improved, but the risk of damage from thermal events, explosions, or fires increases

Engineering Contradiction:

Improveenergy outputVSAvoiddamage from thermal events

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

A force-absorbing device with energy-absorbing elements is integrated into the cooler block structure before accidents occur. These elements are pre-positioned to absorb and distribute impact forces during crashes, preventing direct transmission to the storage cells and double layer capacitors, thereby cushioning them against damage from thermal events, explosions, or fires that could result from mechanical damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Temperature

If electrochemical storage cells and double layer capacitors are cooled from the outside, then heat dissipation is improved, but the complexity of the cooling system increases

Engineering Contradiction:

Improveheat dissipationVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling system is merged with the force-absorbing device structure. The cooler block serves dual functions: it provides thermal management through external cooling channels while simultaneously forming part of the protective structure with energy-absorbing elements. This integration reduces overall system complexity by combining two separate subsystems into one unified component.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a force-absorbing device is integrated into the cooler block, then protection against mechanical damage is improved, but the device complexity increases

Engineering Contradiction:

Improveprotection against mechanical damageVSAvoiddevice structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooler block is designed with multi-functionality, serving both as a thermal management system and as a protective structure with force-absorbing capabilities. The energy-absorbing elements are integrated directly into the cooler block, allowing it to perform multiple functions simultaneously. This universal design reduces the need for separate protective components, thereby managing complexity while improving reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Force

If the force-absorbing element projects beyond the cooler block, then the ability to absorb external forces is improved, but the volume of the device increases

Engineering Contradiction:

Improveforce absorption capabilityVSAvoiddevice volume

Core Design Contradiction:

ForceVSVolume of moving object

Solution Approach 1:

The force-absorbing elements are strategically positioned only at specific locations where impact forces are most likely to occur, rather than uniformly distributing them throughout the entire cooler block. This localized approach provides effective force absorption capability while minimizing the additional volume required, as elements are placed only where needed for protection.

Inventive Principle:

Principle #3Local quality

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 effectively absorbs and diverts forces during a crash, preventing damage to storage cell modules and ensuring reliable heat dissipation, thereby enhancing the safety and service life of the power supply system while maintaining a compact and stable design.

Implementation Method 1

a force absorbing device with at least one—in particular, plate-shaped—force absorbing element, by which in the case of a crash a force acting on the device is absorbed and is diverted around the storage cell modules

Methodology Applied

Scientific EffectForce absorption: Damping

Implementation Method 2

a structure for dissipating the heat emitted by the storage cell module(s)

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Data Source

PatentUS8871372B2Device that is intended for supplying power to a motor vehicle and comprises a cooler block

Publication Date: 2014.10.28 BAYERISCHE MOTOREN WERKE AG

AI summary

A device for supplying power to a motor vehicle, in particular a passenger vehicle, truck or motorcycle, includes one or more storage cell modules, each of which includes one or more electrochemical storage cells and/or double layer capacitors that are arranged next to and/or on top of one another. The device has a cooler block that includes a holder for the storage cell modules and a structure for dissipating the heat emitted by the storage cell modules. The cooler block has a force absorbing device with at least one—in particular, plate-shaped—force absorbing element, by which in the case of a crash a force acting on the device is absorbed and is deflected around the storage cell modules.