Spring Mounting for Battery Thermal Pipes

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Solution Overview

Problem

Existing thermal regulation devices for electric vehicle batteries face issues with spring misalignment and reduced thrust force due to the length of the spring, leading to inefficient heat exchange and battery temperature regulation, which affects the reliability and performance of the vehicle.

Innovation Solution

A tube support system with a transversely arcuate spring and a base that includes lugs and beads to ensure precise positioning and controlled deformation of the spring, maintaining effective contact between the heat exchanger tubes and the battery cells, optimizing the thrust force distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a long spring (200-500 mm) is used to push the heat exchanger tubes against the battery, then the thermal contact between tubes and batteries is improved, but the thrust force is reduced at each end of the spring due to its length

Engineering Contradiction:

Improvethermal contact between tubes and batteriesVSAvoidthrust force at spring ends

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The spring is divided into multiple segments or sections along its length, with intermediate support points provided by the base structure. This segmentation allows the spring to maintain better thrust force distribution by reducing the effective unsupported length, while still achieving the required overall compression to ensure thermal contact between tubes and batteries.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base structure acts as an intermediary element that provides intermediate support to the long spring. By introducing these intermediate support points through the base, the system maintains the benefits of a long spring (thermal contact) while mitigating the disadvantage of reduced thrust force at the ends.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the spring is attached to the base using pins distributed along an axis, then the spring is held in position on the base, but the spring can tilt or become misaligned causing lateral offset and fatigue wear

Engineering Contradiction:

Improvespring positioning on baseVSAvoidspring alignment and contact precision

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The mounting structure employs asymmetric features such as inclined legs rather than symmetric pin distributions. This asymmetry provides natural guidance that prevents lateral offset and misalignment, ensuring the spring remains properly positioned without requiring multiple pins that could allow tilting.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The spring itself has a curved or arcuate geometry that works in conjunction with the base structure. This curvature provides inherent alignment characteristics that prevent misalignment and ensure proper contact between the spring and base, eliminating the need for pin-based positioning systems.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of operation

If pins are used to attach the spring to the base, then the spring is secured in the operating position, but incorrect positioning results in lateral offset affecting thrust effectiveness and causing fatigue wear

Engineering Contradiction:

Improvespring attachment to baseVSAvoidspring contact point positioning accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The spring and base structure are designed to self-align during assembly. The geometric features of the base (such as inclined legs or curved surfaces) automatically guide the spring into the correct position, eliminating the need for precision pin-based attachment systems and reducing manufacturing complexity.

Inventive Principle:

Principle #25Self-service

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 solution ensures reliable and uniform temperature regulation of the battery by preventing spring misalignment and optimizing the thrust force, enhancing the battery's performance and longevity.

Implementation Method 1

a spring (6) which extends in the longitudinal direction (L) and is assembled by interlocking to the base (5), wherein the base (5) has at least two spring support ridges (21) on its lower face oriented towards the spring (6)

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The heat transfer fluid can thus absorb the heat emitted by each battery in order to cool them or, as needed, it can supply them with heat if the battery temperature is insufficient for its proper functioning

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP3328679B1Mounting of thermal-conditioning pipes of a motor vehicle battery, comprising a base provided with a spring

Publication Date: 2021.05.26 VALEO SYST THERMIQUES SAS

Figure 1~2
Figure 3(a)~4
Figure 5~7

AI summary

The invention relates to a pipe mounting 4, intended for keeping a fluid-circulation pipe 3 urged against a vehicle battery in order to control the temperature thereof, the pipe mounting 4 including a base 5 and a spring 6 which extend longitudinally and are assembled with one another by an assembly means, characterised in that the assembly means includes at least two supports between the base 5 and the spring 6 configured to limit a transverse mobility of the spring 6 relative to the base 5, the assembly means being configured to generate a force for straightening the spring 6.