Segmented Battery Pack Assembly With Bendable Channel Cooling
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Solution Overview
Problem
The existing methods for producing energy stores, such as electrical traction batteries for vehicles, are time-intensive and cost-intensive, making them inflexible and unable to meet high quality requirements while maintaining low costs.
Innovation Solution
A method involving a channel element, where energy storage cells are alternately arranged in segments and bent to form a meandering shape, allowing for adaptable geometry and flexible production, using materials like aluminum extrusion profiles, with thermally conductive casting compounds and rotary arms for efficient assembly and cooling, enabling the production of energy stores with varying shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional methods are used to produce energy stores with large numbers of cells, then the required energy capacity is achieved, but the construction becomes time-intensive and cost-intensive
Solution Approach 1:
The energy store is divided into multiple segments, each containing a subset of energy storage cells. These segments are arranged in rows and connected through a channel element, allowing parallel assembly and reducing overall construction time while maintaining total energy capacity.
Solution Approach 2:
Multiple rows of energy storage cells are nested within a three-dimensional framework defined by channel elements. The channel element serves as a common structural backbone that holds multiple cell rows in organized segments, enabling compact arrangement and efficient assembly.
2Stability of the object's composition
If conventional rigid assembly methods are used, then structural stability is achieved, but flexibility in adapting to different vehicle requirements is lost
Solution Approach 1:
The channel element is designed with formable regions that allow it to be bent into different configurations (straight, L-shaped, U-shaped, meandering). This dynamic adaptability enables the same basic structure to accommodate various energy store geometries required by different vehicle applications while maintaining structural integrity through proper connection of segments.
3Temperature
If complex cooling systems are added to meet high quality requirements, then temperature control is improved, but device complexity and costs increase
Solution Approach 1:
The channel element serves multiple functions simultaneously: it provides structural support for the energy storage cells, enables mechanical connections between segments, and acts as a thermal management conduit. The channel element can be configured with internal passages for coolant flow, integrating cooling functionality into the existing structural framework without adding separate complex cooling systems.
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
This method allows for rapid, flexible, and cost-effective production of high-quality energy stores with adaptable shapes and sizes, enhancing production efficiency and reducing costs while maintaining high performance.
Implementation Method 1
arranging the segments beside each other by forming, in particular bending in regions or portions, the channel element in regions
Implementation Method 2
The channel element is advantageously configured and provided to condition the energy storage cells, in particular to control the temperature thereof, for example, to heat or in particular to cool them
Data Source
AI summary
A method for producing an energy store includes providing a channel element with an alternate arrangement of rows of energy storage cells for forming segments which are spaced apart from each other along a longitudinal direction of the channel element, arranging the segments to one another by reshaping some parts, in particular bending some regions or sections, of the channel element, so that the rows are oriented in parallel.