Stackable Battery Module Assembly With Tool-Free Cooling Channels
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Solution Overview
Problem
Traditional battery systems for electric vehicles require fasteners and tools for assembly, leading to increased production costs, weight, and complexity, while also posing challenges for efficient cooling and potential short circuits.
Innovation Solution
A stackable battery module system that eliminates the need for fasteners by using centering elements on the battery module housings to secure and center the modules within the battery system housing, and incorporates a tongue and groove concept for efficient cooling without additional seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw connections are used to secure battery modules, then reliable attachment is achieved, but production costs, weight, and assembly complexity increase
Solution Approach 1:
The patent removes fasteners (screws, bolts, clips) from the battery module assembly system. Instead of using separate fastening components, the housing itself is designed with integrated attachment features that directly secure the battery module stack, eliminating the need for additional fastening elements and simplifying the overall structure.
Solution Approach 2:
The patent combines the housing structure with the attachment function. The housing is designed to integrate the battery module stack retention function directly into its structure, merging what were previously separate components (housing and fasteners) into a unified design that reduces part count and assembly complexity.
2Reliability
If fasteners and tools are used for assembly, then secure attachment is achieved, but production time and material expenditure increase
Solution Approach 1:
The housing structure is designed to be self-securing through its integrated attachment features. The housing itself performs the function of fastening the battery module stack without requiring external fasteners or specialized assembly tools, enabling tool-free assembly and improving production efficiency.
3Temperature
If additional seals are used for cooling channels, then cooling effectiveness is improved, but production costs and component count increase
Solution Approach 1:
The patent combines the cooling channel structure with the sealing function. The cooling channels are designed to be self-sealing through their geometric configuration, merging what were previously separate functions (cooling and sealing) into a unified structure that eliminates the need for additional seal components.
4Reliability
If multiple fasteners are used to secure battery modules, then attachment reliability is improved, but weight and production costs increase
Solution Approach 1:
The patent removes multiple fasteners from the battery module assembly, eliminating the weight of these components. The housing is designed to provide secure attachment through its integrated features without requiring the additional metal fastening elements that contribute to overall system weight.
Data Source
AI summary
A stackable battery module for a battery system of a battery electric vehicle includes a plurality of battery cells and a battery module housing arranged to frame the plurality of battery cells. A plurality of battery modules interlock to form a battery module stack and laterally encase the battery module stack when several battery modules are stacked. The battery module includes centering elements arranged on the outside surfaces of the battery module housing to secure and center the stacked battery module inside a housing of the battery system. The battery module housing has a laterally framing tongue element and a laterally framing groove element corresponding to the tongue element. The tongue element of one battery module interlocks with the groove element of further battery module when the battery modules are stacked with an additional battery module to form a battery module stack and a coolant channel between the battery modules.