Modular Battery Cooling Element for Fast EV Pack Assembly
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Solution Overview
Problem
Existing cooling systems for electric vehicle batteries are costly and time-consuming to manufacture, and require extensive assembly due to their bespoke design for individual vehicle models, making them inefficient and bulky.
Innovation Solution
A modular cooling element with quick-coupling connections and a compact design, featuring a pipe with apertures for easy assembly and connection, allowing for flexible adaptation to different vehicle types, made from polymeric or metal materials using injection molding or extrusion processes, which reduces production costs and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated cooling systems are designed for each vehicle model, then cooling performance is optimized, but manufacturing cost and assembly time increase significantly
Solution Approach 1:
The cooling system is divided into modular cooling elements that can be independently manufactured and assembled. Each cooling element includes a pipe with integrated secondary pipes and quick-coupling means, allowing the system to be segmented into standardized units that can be configured for different vehicle models without redesigning the entire system.
Solution Approach 2:
The cooling element is designed with universal features including standardized quick-coupling connections and modular architecture that can be adapted to multiple vehicle models. The pipe can be configured with different numbers and positions of secondary pipes to serve various cooling requirements while using the same basic component design.
2Reliability
If secondary pipes are fitted onto main pipe with elastic deformation and corrugations, then fluid tightness is ensured, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The secondary pipes are integrated directly into the main pipe as a single molded component rather than separate parts requiring assembly. The quick-coupling means are built-in features of the pipe structure itself, eliminating the need for separate fastening mechanisms and reducing assembly steps while maintaining fluid tightness.
Solution Approach 2:
The pipe structure includes self-sealing features where the connection between secondary pipes and main pipe automatically ensures fluid tightness through the molding process. The quick-coupling means are designed to self-align and self-lock during assembly, reducing the need for complex adjustment procedures.
3Reliability
If bespoke cooling systems are manufactured for individual vehicle models, then cooling efficiency is maximized, but production cost increases
Solution Approach 1:
The cooling system uses standardized modular cooling elements that can be mass-produced independently and then configured for specific vehicle models. This segmentation allows for economies of scale in manufacturing common components while still providing model-specific cooling solutions through different configurations of the same basic units.
Solution Approach 2:
A single standardized cooling element design can serve multiple vehicle models through different configurations. The pipe can be manufactured with varying numbers, positions, and types of secondary pipes to match different cooling requirements, all using the same fundamental component architecture and manufacturing process.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7b
AI summary
Cooling element (1) for an electric component, in particular an electric battery of an electric or hybrid vehicle, comprising: a pipe (2) for a coolant, having two apertures at two ends (10, 16) of the pipe (2), and at least one secondary aperture (4); at least one external connecting pipe (28) fluidically connected to the at least one secondary aperture (4). The external connecting pipe (28) is connected to the secondary aperture (4) through quick-coupling means.