Corrugated Battery Assembly Layout for Compact Thermal Control
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Solution Overview
Problem
Existing battery assemblies for motor vehicles are complex, costly, and space-consuming, with inadequate thermal management and safety features, particularly in accommodating multiple battery modules.
Innovation Solution
A battery assembly design featuring corrugated heat exchange panels with alternating peaks and troughs, housing battery modules in staggered rows, and utilizing thermal control fluid conduits for optimized cooling and safety, with simple and economical manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heat exchangers are used for battery modules, then temperature control is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the heat exchange function directly into the battery module housing structure. The housing serves dual purposes: structural containment and thermal management through integrated cooling channels, eliminating the need for separate traditional heat exchanger components.
Solution Approach 2:
The battery module housing is designed to perform multiple functions simultaneously: mechanical protection of battery cells, structural support, and active thermal management through integrated fluid flow conduits. This multi-functional design reduces overall system complexity.
2Temperature
If traditional heat exchangers are used for battery modules, then temperature control is achieved, but manufacturing cost increases
Solution Approach 1:
By merging the heat exchange function into the housing structure, the patent eliminates the need for separate heat exchanger components, reducing part count, assembly steps, and manufacturing costs while maintaining effective thermal management.
3Quantity of substance
If traditional battery assembly layouts are used, then battery modules can be accommodated, but space consumption increases
Solution Approach 1:
The patent employs a three-dimensional staggered arrangement of battery modules with alternating offset positions in adjacent layers. This spatial optimization allows maximum module density within the assembly volume, efficiently utilizing available space through vertical and horizontal positioning strategies.
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 allows for a compact, efficient, and cost-effective battery assembly that can accommodate numerous modules with enhanced thermal management and safety features, adaptable to vehicle power requirements.
Implementation Method 1
each battery module being housed in at least one crenelation so as to exchange heat with the fluid
Implementation Method 2
a fluid flow conduit being formed at at least one of the trough of each crenelation and the peak of each crenelation
Data Source
AI summary
A battery assembly for a motor vehicle includes: heat exchange panels arranged one above another along a first axis, each heat exchange panel being corrugated in the form of crenelations including, in alternation and along a second axis orthogonal to the first axis, a peak and a trough, a fluid flow conduit being formed at at least one of the trough of each crenelation and the peak of each crenelation; and battery modules arranged in parallel and staggered, each battery module including at least one battery cell in pouch form, each battery module being housed in at least one crenelation so as to exchange heat with the fluid. A method for manufacturing such a battery assembly is also disclosed.