Tolerance Compensation Unit for Electric Vehicle Battery Thermal Management
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Solution Overview
Problem
Existing traction battery systems for electric vehicles face impaired heat conduction due to air gaps between battery modules and housing bases, leading to reduced cooling efficiency and increased weight and manufacturing costs when using thermal paste to fill these gaps.
Innovation Solution
A tolerance compensation unit is introduced, featuring a centering contour on the base body that aligns with a housing-side counter contour, allowing for automatic alignment of the stop sleeve and internal thread, enabling a simple plug connection and reducing component complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal paste is used to fill air gaps between battery modules and housing base, then heat conduction is improved, but weight and manufacturing costs increase
Solution Approach 1:
The patent removes the housing flange entirely, eliminating the source of air gaps between battery modules and housing base. By integrating the mounting function directly into the housing body through recesses and fastening elements, the design extracts the problematic flange component and its associated tolerance issues, allowing thermal paste to be used minimally or eliminated altogether.
Solution Approach 2:
The patent merges the housing flange function with the housing base by creating recesses directly in the housing body that receive battery modules. The fastening elements are integrated into the housing structure rather than being separate flange components, combining multiple functions into a unified structure that eliminates air gaps and reduces the need for thermal paste.
2Temperature
If thermal paste is used to fill air gaps between battery modules and housing base, then heat conduction is improved, but manufacturing costs increase
Solution Approach 1:
By removing the housing flange and the associated air gaps it creates, the patent eliminates the need for large amounts of thermal paste, thereby reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The housing body with integrated recesses and fastening elements performs the mounting function self-sufficiently without requiring a separate flange structure. This self-integrated design reduces assembly steps and manufacturing complexity, lowering production costs while maintaining effective thermal contact.
3Strength
If housing flange is used to mount battery modules, then structural support is provided, but air gaps arise impairing heat conduction
Solution Approach 1:
The patent extracts the housing flange component that creates air gaps and replaces it with recesses integrated into the housing base. This elimination of the flange removes the source of thermal contact issues while preserving the structural support function through the recess design and fastening elements.
Solution Approach 2:
The structural support function previously provided by the separate housing flange is merged into the housing base itself through the recess structure. The fastening elements integrate the battery module mounting and thermal contact functions into a single unified structure, eliminating air gaps while maintaining strength.
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 simplifies the assembly process, reduces component weight, and enhances thermal conductivity by ensuring proper alignment and minimal thermal paste usage, thereby improving cooling efficiency and manufacturing efficiency.
Implementation Method 1
The stop sleeve is in a releasable drive connection (in particular a frictional connection) with the threaded bolt guided by the stop sleeve. During a tolerance compensation procedure, the threaded bolt takes the stop sleeve with it when it is screwed into the housing flange internal thread.
Implementation Method 2
The battery modules can be cooled by means of a cooling system arranged outside the battery housing in order to increase the battery operability.
Data Source
AI summary
A traction battery for an electrically operated vehicle, having a battery housing having a housing base, on which at least one battery module rests in a heat-conducting manner, which has an installation section, which can be clamped via a threaded bolt on a housing flange of the battery housing, wherein in the clamped state the threaded bolt is screwed together with a housing flange internal thread and the battery module installation section is clamped between a bolt head of the threaded bolt and the housing flange, specifically with a tolerance compensation unit interposed, which is supported between the battery module installation section and a housing flange upper side facing away from the housing base, wherein the tolerance compensation unit has a stop sleeve.