Embedded Fluid Conduits in Plastic Battery Housings
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Solution Overview
Problem
The provision of fluid conduits within electric vehicle battery housings is costly and complex, with methods such as screw fixation and snap-in connections being inadequate due to high effort and durability issues.
Innovation Solution
Integrating the fluid conduit into the housing wall itself through blow molding or thermoforming, using plastic materials with additives for enhanced thermal conductivity, and embedding it partially or fully within the wall to achieve a robust and efficient temperature control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum plates with fluid conduits are attached by screws to housing shells, then the fluid conduit can be provided within the battery housing, but the manufacturing effort and cost become quite high
Solution Approach 1:
The patent merges the housing wall and fluid conduit into a single integrated component. The fluid conduit is embedded directly into the housing wall made of plastic, eliminating the need for separate aluminum plates and screw connections. This integration reduces manufacturing steps while maintaining connection durability through the embedded structure.
Solution Approach 2:
The patent replaces the mechanical screw fixation system with an embedding approach where the fluid conduit is integrally formed within the housing wall material. This substitution eliminates complex mechanical fastening operations while achieving reliable connection through the monolithic structure.
2Ease of manufacture
If adhesive fixation is used for aluminum plates, then the manufacturing process is simplified, but the connection is not robust enough due to temperature fluctuations
Solution Approach 1:
The housing wall and fluid conduit are merged into a single integral structure through embedding. The conduit becomes part of the housing wall material itself, creating a robust connection that inherently withstands temperature fluctuations without relying on adhesives or mechanical fasteners.
Solution Approach 2:
The patent uses composite material approach by embedding the fluid conduit within the plastic housing wall material. This creates a composite structure where the conduit and housing material work together as a unified system, providing both simplicity and robustness simultaneously.
3Ease of operation
If snap-in connections are used to fix aluminum plates, then the assembly is simplified, but the connection complexity and effort remain too high
Solution Approach 1:
The patent eliminates snap-in connections by merging the fluid conduit directly into the housing wall. This integration removes the entire class of connection mechanisms, simplifying both assembly operation and reducing structural complexity to the essential function of housing and fluid transport.
4Ease of manufacture
If plastic housing wall is used instead of aluminum plates, then manufacturing effort is reduced, but thermal conductivity may be insufficient for effective temperature control
Solution Approach 1:
The patent employs composite materials by incorporating thermally conductive additives into the plastic housing wall material. This creates a composite plastic material that maintains the manufacturing advantages of plastic while achieving the thermal conductivity properties traditionally associated with metals like aluminum.
Solution Approach 2:
The patent changes the thermal parameters of the plastic material by adding conductive fillers or modifiers. This parameter modification allows the plastic housing wall to achieve sufficient thermal conductivity for effective battery temperature control while retaining all the manufacturing advantages of plastic materials.
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
This approach reduces manufacturing effort and costs while providing a durable, high-performance temperature control system that maintains battery cells at optimal temperatures, enhancing driving performance and enabling fast charging.
Implementation Method 1
plastic materials for the housing wall are sufficiently thermally conductive due to their great design diversity to achieve a high-performance temperature control
Implementation Method 2
by means of blow molding or thermoforming, the fluid structure or fluid conduit can be integrated into the housing wall or into the wall body itself
Implementation Method 3
by means of blow molding or thermoforming, the fluid structure or fluid conduit can be integrated into the housing wall or into the wall body itself
Data Source
AI summary
A battery housing for an electric vehicle battery includes a housing wall comprised of a plastic. The battery housing comprises a fluid conduit for a temperature-regulating means. The fluid conduit is at least partially embedded in the housing wall.