Traction Battery Frame With Integrated Cooling And Underride Guard

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Solution Overview

Problem

Traction batteries in motor vehicles face complex construction issues, inadequate cooling, and insufficient protection against obstacles, leading to potential damage during driving.

Innovation Solution

A simplified traction battery design featuring a battery frame composed of supports with integrated module housings that serve as cooling panels, an underride guard panel, and spring-elastically deformable elements to cushion impacts, allowing effective cooling and protection against obstacles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a complex construction is used for the traction battery, then the structural strength may be improved, but the cooling efficiency deteriorates and the device complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The module housing base wall is merged with the cooling panel function, combining structural support and cooling into a single component. The battery frame supports are welded to form an integrated structure that provides both mechanical strength and cooling pathways, eliminating the need for separate cooling components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The base wall of the module housing serves multiple functions: it provides structural support for the battery cells, acts as a cooling panel with integrated coolant flow channels, and serves as a mounting surface. The frame supports simultaneously provide mechanical strength and form cooling channels.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a complex construction is used for the traction battery, then the structural strength may be improved, but the cooling efficiency deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidcooling efficiency

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling panel acts as an intermediary between the battery cells and the coolant flow. The frame supports serve as intermediaries that conduct heat away from the battery modules while maintaining structural integrity, facilitating heat transfer from the cells to the cooling medium.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If insufficient protection is provided against obstacles, then the device complexity remains low, but the reliability deteriorates when driving over obstacles

Engineering Contradiction:

Improvedevice complexityVSAvoidprotection against damage

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The underride guard panel is positioned beforehand to intercept and absorb impact forces from obstacles before they can reach the battery modules. The spring-elastically deformable elements are pre-installed to provide cushioning, allowing the guard panel to move upward elastically during impact rather than transmitting full force to the battery components.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Manufacturing precision

If the base wall does not protrude on narrow sides, then the manufacturing precision may be improved, but the cooling efficiency deteriorates

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidcooling efficiency

Core Design Contradiction:

Manufacturing precisionVSTemperature

Solution Approach 1:

The base wall is designed to protrude on the narrow sides in advance, creating built-in connection points for coolant supply and discharge. This preliminary structural feature allows coolant connections to be directly integrated into the cooling panel without requiring additional external piping or complex mounting arrangements.

Inventive Principle:

Principle #10Preliminary action

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

The design provides reliable cooling for battery cells and enhanced protection against damage from obstacles, maintaining a simple and efficient structure.

Implementation Method 1

the base wall of the respective module housing is designed as a cooling panel for cooling the battery cells of the respective battery module

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 2

The base wall and the side walls of the respective module housing are preferably screw-connected to one another. The module housings are connected, preferably screw-connected, to the battery frame.

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

spring-elastically deformable elements to cushion impacts

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 4

an underride guard panel which is connected to the battery frame

Methodology Applied

Scientific EffectImpact force absorption: Impact Force

Data Source

PatentUS10811649B2Traction battery of a motor vehicle

Publication Date: 2020.10.20 DR ING H C F PORSCHE AG

AI summary

Traction battery of a motor vehicle includes a battery frame which is assembled from supports. A plurality of battery modules are accommodated in the battery frame and are each composed of a plurality of battery cells which are accommodated in a module housing of the respective battery module. The respective module housing is assembled from side walls and a base wall. The base wall of the respective module housing is designed as a cooling panel for cooling the battery cells. A cover panel is connected to is the battery frame. An underride guard panel is connected to the battery frame.