Modular Battery Support Structure with Integrated Cooling
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Solution Overview
Problem
Existing battery systems for hybrid and electric vehicles face challenges in achieving increased stability and adaptability while minimizing weight, particularly due to the growing number of battery modules and the need for efficient temperature control within limited and irregularly shaped spaces.
Innovation Solution
A modular supporting structure comprising a bottom plate and two side plates with flanges and fixation means, allowing for assembly and adaptation of dimensions, integrated fluid channels for temperature control, and a self-supporting design that eliminates the need for additional carrier plates, enabling flexible and stable battery system configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery modules is increased to enable longer vehicle range, then the battery capacity is improved, but the weight and required stability of the carrier plate increase
Solution Approach 1:
The battery system is divided into multiple modular supporting structures that can be independently manufactured and assembled. Each module contains a defined number of battery cells arranged in a standardized configuration, allowing the overall battery capacity to be scaled by adding or removing modules rather than increasing the size of individual carrier plates.
Solution Approach 2:
The supporting structure serves multiple functions simultaneously: it provides mechanical support for battery cells, integrates fluid channels for thermal management, and includes flanges for modular assembly. This multi-functionality eliminates the need for separate carrier plates and cooling plates, reducing overall system weight while maintaining the required stability for increased battery capacity.
2Stability of the object's composition
If the carrier plate is strengthened to support increased battery module weight, then the stability is improved, but the weight of the whole system increases
Solution Approach 1:
The supporting structure merges the carrier plate function with the cooling plate function into a single integrated component. Fluid channels are incorporated directly into the supporting structure, eliminating the need for a separate heavy-duty carrier plate while maintaining both mechanical stability and thermal management capabilities.
Solution Approach 2:
The supporting structure is made from aluminum or aluminum alloys, which provide high strength-to-weight ratio. This allows the structure to maintain the required stability for increased battery module weight while minimizing the added weight compared to traditional steel carrier plates.
3Temperature
If battery cells are placed directly on a cooling plate, then heat transfer efficiency is improved, but additional building parts and installation requirements increase
Solution Approach 1:
The cooling function is merged directly into the supporting structure by incorporating fluid channels within the aluminum alloy material itself. Battery cells are placed directly on this integrated cooling surface, maximizing heat transfer efficiency while eliminating separate cooling plates and reducing installation complexity.
4Adaptability or versatility
If the battery system shape is adapted to limited and irregular vehicle spaces, then the adaptability is improved, but the structural stability may be compromised
Solution Approach 1:
The battery system is segmented into standardized modular supporting structures that can be arranged in different configurations to fit various vehicle spaces. Each module maintains its structural integrity through standardized flange connections, allowing adaptability to irregular spaces while preserving structural stability through consistent modular design.
Solution Approach 2:
The modular supporting structures include flanges that extend in multiple directions, enabling connection in various orientations and configurations. This allows the battery system to be adapted to three-dimensional irregular vehicle spaces while maintaining structural stability through multi-directional flange connections.
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 a cost-effective, adaptable, and lightweight modular battery system with enhanced mechanical stability and integrated temperature control, reducing assembly and production costs while accommodating varying vehicle spaces and ensuring efficient heat transfer.
Implementation Method 1
a bottom plate and two side plates arranged on the bottom plate, wherein the inner sides of the two side plates and the bottom plate define an internal volume for receiving the battery cells
Implementation Method 2
the bottom plate comprises a fluid channel for receiving a temperature control fluid for controlling the temperature of the internal volume
Implementation Method 3
each flange comprises fixation means for fastening the supporting structure to an adjacent supporting structure
Data Source
AI summary
The present invention pertains to a supporting structure for receiving battery cells in a battery system of a hybrid or electrical vehicle, the supporting structure comprising a bottom plate and two side plates arranged on the bottom plate, wherein the inner sides of the two side plates and the bottom plate define an internal volume for receiving the battery cells and wherein each side plate comprises a flange at its outer side and wherein each flange comprises fixation means for fastening the supporting structure to an adjacent supporting structure.