High-Voltage Energy Storage Device Cooling Structure
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Solution Overview
Problem
Conventional high-voltage energy storage devices for electric vehicles face challenges in efficient cooling, cost, and ease of maintenance due to complex heat transfer processes, thin cooling profiles, and the need for gap fillers, which increase reworking rates and require high forces for module removal.
Innovation Solution
A method for producing a high-voltage energy storage device with a base cooling structure and side wall structure, where storage modules are materially bonded to the base cooling structure for efficient heat transfer and the structures are connected in a reversibly detachable manner to facilitate easy module removal and maintenance, using a seal element to prevent coolant escape and enhance accident behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If storage modules are materially bonded to the base cooling structure for efficient heat transfer, then cooling efficiency is improved, but module removal requires high forces making maintenance difficult
Solution Approach 1:
The connection between the base cooling structure and side wall structure is made dynamically reversible rather than permanently fixed. The fastening elements allow the base cooling structure to be detached from the side wall structure, enabling storage module removal while maintaining thermal contact during operation. This resolves the contradiction by making the connection strong during operation but removable for maintenance.
Solution Approach 2:
The battery housing is segmented into separate components: a base cooling structure and a side wall structure that can be detached from each other. This segmentation allows the storage modules to remain materially bonded to the base cooling structure for heat transfer while the base itself can be removed from the side walls for module access and maintenance.
2Temperature
If a complex cooling structure with thin cooling profiles and gap fillers is used, then cooling performance is improved, but manufacturing complexity and reworking rates increase
Solution Approach 1:
The cooling ducts are merged directly into the base cooling structure itself rather than being separate thin-walled profiles. The base cooling structure contains integrated cooling ducts that receive coolant directly, eliminating the need for separate thin cooling profiles and gap fillers. This reduces manufacturing complexity while maintaining effective cooling performance.
Solution Approach 2:
The problematic thin cooling profiles and gap filler requirements are extracted/removed from the design. Instead of using thin-walled cooling profiles that require precise gap filling, the invention uses a robust base cooling structure with integrated cooling ducts that eliminate the need for gap fillers, thereby reducing manufacturing complexity and reworking rates.
3Ease of repair
If the base cooling structure and side wall structure are connected in a reversibly detachable manner, then ease of maintenance is improved, but structural cohesion may be weakened
Solution Approach 1:
The fastening elements provide a dynamic connection that achieves both strong structural cohesion during normal operation and reversible detachment for maintenance. The fastening mechanism maintains rigid structural integrity when assembled while allowing controlled disassembly, resolving the apparent contradiction between strength and ease of repair.
4Temperature
If storage modules are firmly bonded to the base cooling structure, then heat transfer efficiency is improved, but reworking rates increase due to high forces required for removal
Solution Approach 1:
The system uses dynamically reversible connections at the structural level (base to side walls) while maintaining stable thermal contact between storage modules and the base cooling structure. This allows efficient heat transfer during operation but enables module removal through detachment of the base from side walls, reducing reworking rates.
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 method enables effective and cost-efficient cooling, reduces reworking rates, and improves accident behavior by allowing simple and quick removal of storage modules for maintenance or replacement, while preventing coolant leakage and ensuring a strong structural cohesion.
Implementation Method 1
storage modules are materially bonded to the base cooling structure for efficient heat transfer
Implementation Method 2
cooling ducts, which extend between the cover elements and through which a coolant fluid, in particular a coolant liquid, can flow
Data Source
AI summary
A method for producing a high-voltage energy storage device which is designed for storing electric energy, for a motor vehicle, in which storage modules are at least partially arranged in a receptacle space of a storage box of the high-voltage energy storage device, having the following steps: providing a base cooling structure of the storage box wherein the base cooling structure includes two cover elements spaced apart from one another and cooling ducts, which extend between the cover elements and through which a coolant fluid can flow.