Lightweight Molded Battery Element for Efficient Thermal Control
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Solution Overview
Problem
Existing temperature control systems for electrochemical energy storage devices in electric vehicles require significant energy and increase vehicle mass, limiting the usable energy for propulsion.
Innovation Solution
A lightweight molded element composed of plastic, with a density of at most 0.75 g/cm3, is used to displace temperature-control fluid and securely position energy storage elements, allowing efficient temperature control and weight optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional temperature control systems are used for electrochemical energy storage devices, then temperature control function is achieved, but vehicle mass increases and energy consumption increases
Solution Approach 1:
The patent employs a porous molded element made of plastic material with closed-cell foam structure. The porous structure provides thermal management functionality while maintaining low density (at most 0.75 g/cm³), thereby achieving temperature control without significantly increasing vehicle mass
Solution Approach 2:
The invention uses composite material construction combining plastic matrix with dispersed particles or fibers. This composite approach creates a molded element that simultaneously provides structural support, thermal management, and lightweight properties, resolving the contradiction between temperature control capability and vehicle mass
2Temperature
If traditional temperature control systems are used for electrochemical energy storage devices, then temperature control function is achieved, but energy consumption increases
Solution Approach 1:
The molded element is designed to provide passive thermal management through its inherent porous structure and thermal conductivity properties. The element automatically conducts heat away from energy storage devices without requiring active pumping or additional energy input, thereby reducing overall system energy consumption
Solution Approach 2:
The porous structure of the molded element enables natural convection and capillary action for fluid distribution, reducing the need for energy-consuming pumps and active cooling systems while maintaining effective temperature control
3Weight of moving object
If molded element with low density is used, then vehicle mass is reduced, but structural strength may be compromised
Solution Approach 1:
The molded element utilizes composite material construction with plastic matrix reinforced by dispersed particles or fibers. This creates a lightweight structure (density at most 0.75 g/cm³) that maintains adequate structural strength through the synergistic combination of materials
Solution Approach 2:
The invention implements varying material density and composition in different regions of the molded element. Critical load-bearing areas have higher density and reinforcement, while non-critical areas use lower density material, optimizing the strength-to-weight ratio throughout the structure
Data Source
AI summary
A molded element for arranging on a temperature-controllable element, wherein the temperature-controllable element may preferably be an energy storage element, for example an electrochemical energy storage cell, wherein the molded element comprises: at least one receiving zone for receiving at least one section of the temperature-controllable element in the molded element and a molded element material having a density of at most 0.75 g/cm3, preferably at most 0.65 g/cm3, particularly preferably at most 0.55 g/cm3.