Modular Cast Battery Tray With Integrated Cooling Ducts
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Solution Overview
Problem
Existing battery trays for motor vehicles lack the ability to be individually adapted in size and do not incorporate an active cooling system, leading to potential overheating and reduced battery lifespan.
Innovation Solution
A modular battery tray design featuring cast parts with integrated cooling ducts and adjustable modules, allowing for expansion and ensuring pressure-tight and medium-tight connections, which can be customized to fit different battery sizes and equipped with a flow-through cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a battery tray is produced from metal sheets and profiles to ensure rigidity and leak tightness, then structural strength and sealing are improved, but manufacturing complexity and production tolerance requirements increase
Solution Approach 1:
The battery tray is divided into multiple individual cast modules, each capable of being produced separately. This segmentation allows each module to be manufactured with standard tolerances while the final assembly achieves the required overall precision through modular connection, reducing the complexity of producing a single large precision component.
Solution Approach 2:
The patent employs composite construction by joining multiple cast metal modules together to form the complete battery tray. This composite approach combines the advantages of cast components (good strength-to-weight ratio, integrated cooling channels) while distributing manufacturing requirements across multiple simpler components rather than one complex piece.
2Duration of action of stationary object
If an active cooling system is added to the battery tray, then battery service life is improved, but device complexity increases
Solution Approach 1:
The cooling system is merged with the battery tray structure itself by integrating cooling channels directly into the cast modules. This combination eliminates the need for separate cooling components and assemblies, reducing overall system complexity while providing effective active cooling to extend battery service life.
Solution Approach 2:
The cast modules serve multiple functions simultaneously: they provide structural support for the battery cells, form the containment tray, and incorporate integrated cooling channels. This multi-functionality reduces the number of separate components needed, simplifying the overall system while achieving effective cooling.
3Quantity of substance
If the battery tray size is increased to accommodate more battery cells, then energy storage capacity is improved, but the ability to adapt to different battery sizes decreases
Solution Approach 1:
The battery tray is constructed from multiple identical or interchangeable cast modules that can be assembled in different quantities and configurations. This modular segmentation enables the same basic module design to be used for different battery capacities by simply varying the number of modules, maintaining adaptability while accommodating different energy storage requirements.
Solution Approach 2:
The modular design allows the battery tray configuration to be dynamically adjusted by adding or removing modules based on the specific battery capacity requirements. This dynamic adaptability enables a single module design to serve multiple applications with different storage needs without requiring additional tooling or design changes.
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 modular design allows for flexible sizing without additional costs and provides effective cooling, enhancing the battery tray's rigidity, strength, and thermal conductivity, thereby extending battery lifespan and improving performance.
Implementation Method 1
Ducts for a cooling medium are arranged on or in the base section for each of the modules
Implementation Method 2
an active cooling system can be provided in the form of a flow-through cooling duct on the tray
Data Source
AI summary
A battery tray is for at least one battery module for a motor vehicle. The at least one battery module has multiple battery cells. The battery tray includes: a plurality of modules, the modules including: a front module; a rear module; and at least one central module. The modules each include a base section and at least one wall section. Ducts for a cooling medium are arranged on or in the base section for each of the modules. The modules are each embodied as cast parts and are connected to one another by joining to form a closed, pressure-tight and medium-tight battery tray.