Integrated Cooling Element for EV Battery Structural Support
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Solution Overview
Problem
The thermal regulation of electrical storage devices in electric and hybrid motor vehicles is inadequate, leading to potential damage from overheating, reduced autonomy at low temperatures, and mechanical weaknesses in existing thermal regulation systems, which also occupy valuable space and reduce vehicle power and range.
Innovation Solution
A cooling element with integrated structural and thermal regulation functions, featuring channels within the walls to support and cool the electrical storage device, minimizing bulk and risk of fluid leaks, and utilizing extrusion for enhanced mechanical strength and efficient heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal regulation devices are arranged at the bottom of the battery pack protection box under the electrical modules, then thermal regulation function is provided, but mechanical strength is relatively weak and space for battery modules is reduced
Solution Approach 1:
The patent merges the structural support function and thermal regulation function into a single integrated cooling element. The first wall is configured to carry the electrical storage device (structural function) while containing first and second channels for heat transfer fluid circulation (thermal regulation function). This integration eliminates the need for separate structural supports and thermal regulation devices, resolving the contradiction between providing thermal regulation and maintaining mechanical strength.
Solution Approach 2:
The cooling element performs multiple functions simultaneously: it serves as a structural support (first wall configured to carry electrical storage device), a thermal regulation device (channels for heat transfer fluid), and a protective enclosure. This multi-functionality approach allows the same component to provide both mechanical strength and thermal management, eliminating the trade-off between these two requirements.
2Temperature
If thermal regulation devices are arranged inside the battery pack, then thermal regulation is provided, but there is a risk of destruction of modules in the event of leaks of the heat transfer fluid
Solution Approach 1:
The patent extracts the heat transfer fluid circulation system from the interior enclosure and integrates it into the walls themselves. The channels are formed directly in the first wall and second wall, eliminating separate internal thermal regulation devices that could leak. The fluid circulation circuit is contained within the structural walls, reducing the risk of leaks damaging modules.
3Temperature
If thermal regulation devices are arranged inside the battery pack, then thermal regulation is provided, but the space allocated for receiving battery modules is reduced
Solution Approach 1:
By merging the structural support wall and thermal regulation device into a single integrated cooling element, the patent eliminates the need for separate components. The first wall serves both as a structural carrier and as a thermal regulation device with embedded channels, maximizing the use of available space and increasing the volume available for battery modules.
4Temperature
If conventional thermal regulation devices are used, then cooling function is provided, but device complexity and bulk are increased
Solution Approach 1:
The patent combines multiple functions (structural support, thermal regulation, fluid circulation) into a single integrated cooling element with walls containing embedded channels. This integration simplifies the overall device structure, reduces bulk, and eliminates the need for multiple separate components while maintaining effective cooling function.
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 provides effective thermal regulation and structural support, optimizing the arrangement and efficiency of the cooling system while minimizing size and leak risks, ensuring reliable operation and extended lifespan of the electrical storage devices.
Implementation Method 1
a heat transfer fluid which circulates in thermal regulation devices placed inside the protective casing of the battery pack
Implementation Method 2
Coolant from the bottom plate can be circulated through the side plates
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a cooling element (100) of an electrical storage device (200) for a motor vehicle, comprising at least one first wall (110) extending primarily in a first plane and in which is created at least one first channel (113), and at least one second wall (120) extending primarily in a second plane and in which is created at least one second channel (123), wherein a heat transport fluid can travel via the first channel (113) and the second channel (123). According to the invention, the first plane in which the first wall (110) extends and the second plane in which the second wall (120) extends intersect, and at least the first wall (110) is configured to support the electrical storage device (200).