Method for configuring cooling tube of battery pack and cooling tube for battery pack

Abstract

Disclosed is a method for configuring a cooling tube of a battery pack with improved cooling efficiency and a cooling tube of a battery pack. The cooling tube of a battery pack and the method for configuring a cooling tube of a battery pack are characterized in that the cooling efficiency is related to minimizing pressure loss and minimizing deformation.

Description

Method for configuring the cooling tubes of a battery pack and the cooling tubes of a battery pack

[0001] The present invention relates to a method for configuring a cooling tube of a battery pack and a cooling tube of a battery pack, and more specifically, to a method for configuring a cooling tube of a battery pack with improved cooling efficiency and a cooling tube of a battery pack.

[0002] This application is a priority claim application for Korean Patent Application No. 10-2024-0136912 filed on October 8, 2024, and all contents disclosed in the specification and drawings of said application are incorporated into this application by reference.

[0003] Secondary batteries, which possess electrical characteristics such as high energy density and high applicability across product groups, are widely applied not only to portable devices but also to electric vehicles (EVs) or hybrid electric vehicles (HEVs) powered by electric sources. These secondary batteries are attracting attention as a new energy source for enhancing eco-friendliness and energy efficiency, not only for the primary advantage of drastically reducing the use of fossil fuels but also because they generate no by-products from energy use.

[0004] Currently, widely used types of secondary batteries include lithium-ion batteries, lithium-polymer batteries, nickel-cadmium batteries, nickel-hydrogen batteries, and nickel-zinc batteries. The operating voltage of these unit secondary battery cells, or unit battery cells, is approximately 2.5V to 4.5V. Therefore, if a higher output voltage is required, multiple battery cells are connected in series to form a battery pack. Additionally, depending on the charge / discharge capacity required for the battery pack, multiple battery cells are connected in parallel to form a battery pack. Accordingly, the number of battery cells included in the battery pack can be varied according to the required output voltage or charge / discharge capacity. Consequently, the number of battery cells in the battery pack can be adjusted according to the desired output voltage and charge / discharge capacity.

[0005] Meanwhile, when configuring a battery pack by connecting multiple battery cells in series or parallel, it is common practice to assemble the battery pack by adding battery cells and other components.

[0006] In conventional battery packs, cooling tubes are provided between battery cells to cool them. For these cooling tubes, it is important to ensure heat transfer performance and minimize pressure loss to increase cooling efficiency.

[0007] Therefore, it is necessary to explore ways to secure heat transfer performance and minimize pressure loss.

[0008] Accordingly, the objective of the present invention is to provide a method for configuring a cooling tube of a battery pack capable of securing heat transfer performance and minimizing pressure loss, and to provide a cooling tube of a battery pack.

[0009] However, the technical problems that the present invention aims to solve are not limited to those described above, and other unmentioned problems will be clearly understood by those skilled in the art from the description of the invention below.

[0010] To solve the above objective, the present invention provides a method for configuring a cooling tube of a battery pack, comprising the steps of: providing a cooling tube having a plurality of channels through which a cooling medium can pass, wherein the cooling tube defines a length, width, and height, and each channel extends across the length of the cooling tube; changing the number of channels N and the aspect ratio D of the channels in the cooling tube; determining a pressure drop ΔP across the cooling tube for a change in the number of channels N and the aspect ratio D of the channels using the mathematical formula ΔP = f (N, D, L, T), where L is the length of the cooling tube and T is the thickness of a rib separating adjacent channels; and determining a deformation δ of each channel when the cooling tube is bent to fit the arrangement of battery cells of the battery pack using the mathematical formula δ = f (N, D, T), for a change in the number of channels N and the aspect ratio D of the channels. The present invention provides a method for configuring a cooling tube of a battery pack, comprising the step of determining the relationship between the number of channels N, the aspect ratio D of the channels, and the thickness T of the ribs by referring to the pressure drop ΔP and deformation δ so as to maximize the cooling efficiency of the cooling tube, wherein the cooling efficiency is associated with minimizing pressure loss and minimizing deformation.

[0011] Additionally, preferably, the aspect ratio D of each channel can be defined by the height and width of each channel.

[0012] Additionally, preferably, each channel can be defined as an elongated shape with curved top and bottom ends.

[0013] Additionally, preferably, the thickness of each rib T can be the minimum distance between adjacent channels.

[0014] Additionally, preferably, the step of bending the cooling tube may include the step of bending the cooling tube to fit the shape of the first linear array of battery cells of the battery pack.

[0015] Additionally, preferably, the cooling tube can be in contact with each battery cell of the first preceding array.

[0016] Additionally, preferably, the cooling tube is configured to be positioned between the first linear array of battery cells of the battery pack and the second linear array of battery cells, and the first surface of the cooling tube is in contact with the first linear array, and the second surface of the cooling tube is in contact with the second linear array.

[0017] Additionally, preferably, the step of determining the pressure drop ΔP may include the step of determining the pressure drop ΔP across the cooling tube for each change in the number of channels N and the aspect ratio D of the channels based on the viscosity and flow rate of the cooling medium.

[0018] Additionally, preferably, the step of determining the relationship between the factors may include the step of determining the relationship between the number of channels N, the aspect ratio D of the channels, the pressure drop ΔP, and the strain δ using correlation analysis.

[0019] Additionally, preferably, the plurality of channels may include a first channel set and a second channel set, wherein the first channel set allows the inflow of the cooling medium into the cooling tube and the second channel set allows the outflow of the cooling medium from the cooling tube.

[0020] Additionally, preferably, the cooling tube is configured to include five or fewer channels for each of the first channel set and the second channel set, the aspect ratio of each channel is 3.45 or less, and the thickness of the rib may be 0.34 mm or less.

[0021] In addition, preferably, the pressure ΔP per unit length of each channel may be 6.67 kPa / m or less for a cooling medium flow rate of 1 liter / min.

[0022] The present invention provides a cooling tube for a battery pack, comprising a plurality of channels configured to allow a cooling medium to flow through the cooling tube, wherein each channel includes the plurality of channels having an aspect ratio defined by height and width, and the cooling tube is bent to correspond to a first linear array of the battery pack such that a first side of the cooling tube contacts a first linear array of the battery cells, and the plurality of channels and the aspect ratio of each channel are configured to minimize the pressure drop of the cooling medium and minimize channel deformation occurring when the cooling tube is bent, thereby maximizing the cooling efficiency of the cooling tube.

[0023] Additionally, preferably, the plurality of channels may include a first set of channels for the inflow of the cooling medium; and a second set of channels for the outflow of the cooling medium.

[0024] Additionally, preferably, the first channel set is provided between 4 and 6 channels, and the second channel set may be provided between 4 and 6 channels.

[0025] Additionally, preferably, the first channel set has 5 channels, and the second channel set may have 5 channels.

[0026] Additionally, preferably, the aspect ratio of each of the first channel set and the second channel set may be 4 or less.

[0027] Additionally, preferably, the aspect ratio of the first channel set and the second channel set, respectively, may be 3.45.

[0028] Additionally, preferably, ribs can be defined between adjacent channels.

[0029] In addition, preferably, the thickness of the rib may be 0.4 mm or less.

[0030] In addition, preferably, the thickness may be 0.34 mm.

[0031] Additionally, preferably, each channel can be defined as an elongated shape with curved top and bottom ends.

[0032] According to the various embodiments described above, a method for configuring a cooling tube of a battery pack capable of securing heat transfer performance and minimizing pressure loss, and a cooling tube of a battery pack can be provided.

[0033] In addition, various other additional effects may be achieved by various embodiments of the present invention. These various effects of the present invention are described in detail in each embodiment, or the description of effects that are easily understood by those skilled in the art is omitted.

[0034] The following drawings attached to this specification illustrate preferred embodiments of the present invention and serve to further enhance understanding of the technical concept of the present invention together with the detailed description of the invention provided below; therefore, the present invention should not be interpreted as being limited only to the matters described in such drawings.

[0035] FIG. 1 is a schematic diagram illustrating a battery cell array according to one embodiment of the present invention.

[0036] FIG. 2 is a schematic exploded perspective view for illustrating a battery cell array according to one embodiment of the present invention.

[0037] FIG. 3 is a drawing for explaining a cooling tube according to one embodiment of the present invention.

[0038] FIG. 4 is a plan view of battery cells and cooling tubes according to one embodiment of the present invention.

[0039] FIG. 5 is a drawing for illustrating a cooling tube according to another embodiment of the present invention.

[0040] FIG. 6 is a drawing for illustrating a cooling tube according to another embodiment of the present invention.

[0041] FIG. 7 is a drawing for illustrating a cooling tube according to another embodiment of the present invention.

[0042] FIG. 8 is a front view of a cooling tube according to one embodiment of the present invention.

[0043] FIG. 9 is a side cross-sectional view of a cooling tube according to one embodiment of the present invention.

[0044] FIG. 10 is a drawing for explaining a manufacturing process of a cooling tube through a press process according to one embodiment of the present invention.

[0045] FIG. 11 is a drawing for explaining the cross-sectional view of the cooling channels after the press process according to the number of cooling channels of the cooling tube according to one embodiment of the present invention.

[0046] FIG. 12 is a diagram illustrating the differential pressure per unit length according to the number of cooling channels of a cooling tube according to one embodiment of the present invention.

[0047] FIG. 13 is a drawing for explaining the expected differential pressure according to the configuration of a battery cell array according to one embodiment of the present invention.

[0048] FIG. 14 is a schematic diagram illustrating a cooling channel of a cooling tube according to one embodiment of the present invention.

[0049] FIG. 15 is a schematic plan view of a battery cell array to illustrate the arrangement of cooling tubes of a battery cell array according to one embodiment of the present invention.

[0050] Figure 16 is an enlarged view of part E of Figure 15.

[0051] FIG. 17 is a schematic cross-sectional view of a battery cell array to illustrate the arrangement of cooling tubes in the height direction of a battery cell array according to one embodiment of the present invention.

[0052] Fig. 18 is an enlarged view of part F of Fig. 17.

[0053] FIGS. 19 and 20 are drawings for explaining the contact between a cooling tube and a battery cell when there is deformation of the cooling channel of a cooling tube according to an embodiment of the present invention.

[0054] FIG. 21 is a schematic diagram illustrating a battery cell array according to another embodiment of the present invention.

[0055] FIG. 22 is a drawing for illustrating a battery cell array according to another embodiment of the present invention.

[0056] FIG. 23 is a drawing for explaining a battery pack according to one embodiment of the present invention.

[0057] FIG. 24 is a drawing for explaining an automobile according to one embodiment of the present invention.

[0058] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, and should be interpreted in a meaning and concept consistent with the technical spirit of the present invention, based on the principle that the inventor can appropriately define the concept of the terms to best describe his invention.

[0059] Therefore, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention; thus, it should be understood that various equivalents and modifications that can replace them may exist at the time of filing this application.

[0060] Meanwhile, although terms indicating directions such as up, down, left, right, front, and back may be used in this specification, these terms are used merely for convenience of explanation and may vary depending on the location of the object or the position of the observer, as is obvious to those skilled in the art of this invention.

[0061]

[0062] FIG. 1 is a schematic drawing for explaining a battery cell array according to one embodiment of the present invention, and FIG. 2 is a schematic exploded perspective view for explaining a battery cell array according to one embodiment of the present invention.

[0063] Referring to FIGS. 1 and 2, the battery cell array (10) may include battery cells (100) and a cooling tube (200). The battery cell array (10) may be a component of a battery pack (1, see FIG. 23) described below. That is, the battery pack (1, see FIG. 23) described below may include the battery cell array (10).

[0064] The battery cells (100) may be provided in a plurality. The plurality of battery cells (100) may be provided as secondary batteries, such as cylindrical secondary batteries, prismatic secondary batteries, or pouch-type secondary batteries. First, in this embodiment, the battery cells (100) are described as being provided as cylindrical secondary batteries, and cases where the battery cells (102, see FIG. 21) are provided as prismatic secondary batteries or where the battery cells (103, see FIG. 22) are provided as pouch-type secondary batteries will be described in more detail in the following related drawings.

[0065] The cooling tube (200) is provided between the plurality of battery cells (100) and can be attached to the plurality of battery cells (100) to increase cooling performance. Accordingly, the cooling tube (200) may have a cell attachment surface on its outer surface that is attached to the plurality of battery cells (100).

[0066] In the cooling tube (200), a cooling channel (250, see FIG. 9) described later for the flow of a cooling medium may be formed. In one embodiment of the present invention, the cooling medium may be provided as water as a liquid. It is not limited thereto, and the cooling medium may include not only water but also one or more fluids capable of exchanging heat with the surrounding environment. The cell attachment surface of the cooling channel (250, see FIG. 9) may be provided as a flat surface to maximize the contact area with the battery cells (100).

[0067] The cooling tube (200) may be provided with curvature in the longitudinal direction (Y-axis direction) to enhance cooling performance with the battery cells (100) provided as the cylindrical secondary battery. This is intended to increase cooling performance by securing a larger contact area between the outer surface (105) of the battery cells (100) provided in a cylindrical shape and the cooling tube (200). However, in the cooling channel (250) provided within the cooling tube (200), deformation such as a bending shape may occur on the cell attachment surface of the cooling tube (200) according to a press process, etc., described later. If deformation such as bending occurs on the cell attachment surface that contacts the outer surface of the battery cells (100), the flatness of the cell attachment surface is reduced, causing the degree of contact between the outer surface of the cooling tube (200) and the battery cells (100) to decrease, thereby reducing the contact area. As a result, the heat transfer area is reduced, and the heat transfer performance of the cooling tube (200) may be degraded.

[0068] The bending shape resulting from the deformation of the above-mentioned cooling channel (250) may occur during the press process for forming the curvature of the cooling tube (200) described later.

[0069] In one embodiment of the present invention, the cell attachment surface can be secured as a flat surface even after the press process of the cooling tube (200), thereby reducing the risk of deformation of the cell attachment surface of the cooling tube (200) and significantly reducing the risk of heat transfer deviation occurring inside the cooling channel (250) near the cell attachment surface. Therefore, in one embodiment of the present invention, the heat transfer area can be maximized while increasing the adhesion of the battery cells (100) to the cooling tube (200), thereby preventing a decrease in the heat transfer performance of the cooling tube (200).

[0070]

[0071] FIG. 3 is a drawing for explaining a cooling tube according to one embodiment of the present invention, FIG. 4 is a plan view of battery cells and a cooling tube according to one embodiment of the present invention, FIG. 5 is a drawing for explaining a cooling tube according to another embodiment of the present invention, FIG. 6 is a drawing for explaining a cooling tube according to yet another embodiment of the present invention, and FIG. 7 is a drawing for explaining a cooling tube according to yet another embodiment of the present invention.

[0072] Referring to FIGS. 3 and 4, the cooling tube (200) may be made of a material with high thermal conductivity. For example, the cooling tube (200) may be made of aluminum.

[0073] The cooling tube (200) is formed with a predetermined length and may have a curvature shape in the longitudinal direction (Y-axis direction). The curvature shape may be a shape formed by an alternating arrangement of convex and concave portions in the longitudinal direction (Y-axis direction). The alternating arrangement of convex and concave portions may mean that one concave portion is placed between two convex portions, and one convex portion is placed between two concave portions. The plurality of battery cells (100) may be arranged in two rows in the longitudinal direction with the cooling tube (200) in between, and may be arranged to be attached to the convex and concave portions. Here, the two rows of battery cells (100) may be composed of a first linear array and a second linear array composed of a plurality of battery cells (100). The first surface of the cooling tube (200) may be in contact with the first linear array, and the second surface of the cooling tube (200) may be in contact with the second linear array.

[0074] Referring to FIG. 5, the cooling tube (201) may have a shape and structure that accommodates battery cells (100) arranged in at least four rows. Specifically, the cooling tube (201) may be formed to have a length at least twice that of the preceding cooling tube (200) and may have a curvature shape in the longitudinal direction (Y-axis direction). The curvature shape may be a shape formed by an alternating arrangement of convex and concave portions in the longitudinal direction (Y-axis direction). The cooling tube (210) may be formed to extend a predetermined length in one side (+Y-axis direction) in the longitudinal direction (Y-axis direction) and be bent at least once at one end (+Y-axis direction) along the longitudinal direction (Y-axis direction) to extend a predetermined length in the opposite direction (-Y-axis direction). In this way, the cooling tube (201) according to the present embodiment may be formed to be attached to a total of four rows of battery cells (100) by dividing two rows of battery cells (100) into two sets. In addition, the cooling tube (201) is provided with a cooling channel (250, see FIG. 9) similar to the cooling tube (200) mentioned above.

[0075] Referring to FIG. 6, the cooling tube (202) is formed to a predetermined length while having a multiple bending structure and may have a curvature shape in the longitudinal direction (Y-axis direction). The curvature shape may be a shape formed by an alternating arrangement of convex and concave portions in the longitudinal direction (Y-axis direction). Specifically, the cooling tube (202) may be formed as a serpentine structure capable of covering four or more rows of multiple battery cells (100) through two or more multiple bending structures. By using a cooling tube (202) having such a multiple bending structure, integrated cooling of multiple rows of battery cells (100) can be achieved, thereby reducing the number of cooling tubes (202). By using a cooling tube (202) having such a multiple bending structure, it may also be possible to cool multiple rows of battery cells (100) with a single cooling tube (202) depending on the design. Meanwhile, the cooling tube (202) is also equipped with the same cooling channel (250, see FIG. 9) as the aforementioned cooling tube (200).

[0076] Referring to FIG. 7, the cooling tube (203) may be formed to extend to both sides (+Y-axis direction and -Y-axis direction) in the longitudinal direction (Y-axis direction) by a predetermined length from the cooling medium inlet / outlet part (204) connected to an external cooling line, etc. The cooling tube (203) is formed to a predetermined length in each direction (+Y-axis direction and -Y-axis direction) and may have a curvature shape in the longitudinal direction (Y-axis direction). The curvature shape may be a shape formed by an alternating arrangement of convex and concave parts in the longitudinal direction (Y-axis direction).

[0077] In this way, the cooling tube (203) may be provided with a two-way cooling structure in which the cooling medium inlet / outlet part (204) is positioned in the center in the length direction (Y-axis direction) and extends to both sides (+Y-axis direction and -Y-axis direction), respectively.

[0078] In addition, the cooling tube (203) is also equipped with the same cooling channel (250, see FIG. 9) as the aforementioned cooling tube (200).

[0079] In this embodiment, in all of the cooling tubes (200, 201, 202, 203) of the various structures, the cell attachment surface can be secured as a flat surface according to the design structure described below, thereby reducing the risk of deformation of the cell attachment surface of the cooling tubes (200, 201, 202, 203) and significantly reducing the risk of heat transfer deviation occurring inside the cooling channel (250) near the cell attachment surface.

[0080] Accordingly, in one embodiment of the present invention, the heat transfer area can be maximized while increasing the contact degree of the battery cells (100) with the cooling tubes (200, 201, 202, 203), thereby preventing a decrease in the heat transfer performance of the cooling tube (200).

[0081]

[0082] In the following, regarding the shape of the cooling channel (250) according to one embodiment of the present invention, we will examine it in more detail, focusing on the cooling tube (200) as a representative example among the cooling tubes (200, 201, 202, 203). Although the following description is limited to the cooling tube (200), it is understood that it can also be applied to the cooling tubes (201, 202, 203).

[0083] FIG. 8 is a front view of a cooling tube according to one embodiment of the present invention, FIG. 9 is a side cross-sectional view of a cooling tube according to one embodiment of the present invention, and FIG. 10 is a drawing for explaining a manufacturing process of a cooling tube through a press process according to one embodiment of the present invention.

[0084] Referring to FIGS. 8 to 10 and the preceding drawings, the cooling tube (200) can be made to have such a curved shape by applying pressure from a press device (P) during the manufacture of the cooling tube (200). That is, it can be manufactured so that convex and concave parts are alternately formed by applying pressure from the press device (P). In other words, the cooling tube (200) can be bent by applying pressure from the press device (P). Here, the cooling tube (200) can be bent to fit the shape of at least one of the first linear array and the second linear array of the battery cells (100).

[0085] The above cooling channels (250) may be provided in a predetermined number of multiple channels that do not cause deformation of the cooling channels (250) when pressurized. The number of cooling channels (250) is an important design factor related to the deformation of the cooling channels (250) when pressurized. In the cooling tube (200), the more cooling channels (250) there are, the less deformation of the cooling channels (250) can be reduced when pressurized. However, there is a problem that the pressure loss of the cooling tube (200) increases as the number of cooling channels (250) increases. If the pressure loss of the cooling tube (200) is large, the output of the pump for circulating the cooling medium to the cooling channels (250) must be increased, which increases power consumption and causes a problem of reducing the overall efficiency of the battery cell array (10).

[0086] Therefore, in the cooling tube (200), it is important that the number of cooling channels (250) is provided as a predetermined number that reduces the pressure loss and does not cause deformation of the cooling channels (250) during the press process. In one embodiment of the present invention, the cooling channels (250) are provided in 10 numbers and may be spaced apart from each other at a predetermined distance along the height direction of the cooling tube (200).

[0087] The above cooling channel (250) may include an inlet channel (252) and an outlet channel (256).

[0088] The inlet channel (252) can guide the cooling medium supplied from an external cooling device toward the cooling tube (200). This inlet channel (252) can be positioned at the bottom relative to the central axis of the cooling tube (200) in the height direction (Z-axis direction) of the cooling tube (200). The inlet channel (252) is formed to be long along the length direction (Y-axis direction) of the cooling tube (200) and can allow the cooling medium to flow along the length direction (Y-axis direction) from the bottom of the cooling tube (200).

[0089] The inlet channels (252) may be provided in a predetermined number. In this embodiment, the inlet channels (252) are provided in multiple numbers, specifically, five. The number of inlet channels (252) may be a number that takes into account both reducing pressure loss and preventing deformation during the aforementioned press process. These multiple inlet channels (252) may be spaced apart from each other by a predetermined distance along the height direction (Z-axis direction) of the cooling tube (200).

[0090] These plurality of inlet channels (252) may be a first set of channels that allow the inflow of the cooling medium into the cooling tube (200).

[0091] The outlet channel (256) is in communication with the inlet channel (252) and can guide the cooling medium flowing from the inlet channel (252) to the external cooling device. The outlet channel (256) can be positioned above the central axis of the cooling tube (200) in the height direction (Z-axis direction) of the cooling tube (200). Specifically, the outlet channel (256) can be provided above the inlet channel (252) in the height direction (Z-axis direction) of the cooling tube (200). The outlet channel (256) is formed long along the length direction (Y-axis direction) of the cooling tube (200) and can allow the cooling medium to flow along the length direction (Y-axis direction) from the upper part of the cooling tube (200).

[0092] The above outlet channels (256) may be provided in a predetermined number. In this embodiment, the outlet channels (256) are provided in multiple numbers, specifically, five. The number of outlet channels (256) may be a number that takes into account both reducing pressure loss and preventing deformation during the aforementioned press process. The multiple outlet channels (256) may be spaced apart from each other at a predetermined distance along the height direction (Z-axis direction) of the cooling tube (200). In other words, each inlet channel (252) and each outlet channel (256) may be spaced apart at a predetermined interval along the height direction (Z-axis direction) of the cooling tube (200).

[0093] These plurality of outlet channels (256) may be a second set of channels that allow the cooling medium to flow out from the cooling tube (200).

[0094] Meanwhile, the cooling medium may enter the inlet channel (252) through a port connected to an external cooling device of the cooling tube (200), flow along the longitudinal direction of the inlet channel (252), then move toward the outlet channel (256) on the opposite side of the port, flow along the longitudinal direction of the outlet channel (256), and then move again toward the external cooling device through the port. The flow path of the cooling medium may be approximately U-shaped.

[0095]

[0096] Below, we examine test results related to the deformation of the cooling channels (250) during the press process associated with the number of cooling channels (250) of the above-mentioned cooling tube (200).

[0097] FIG. 11 is a drawing for explaining the cross-sectional view of the cooling channels after the press process according to the number of cooling channels of the cooling tube according to one embodiment of the present invention.

[0098] Referring to FIG. 11 and the preceding drawings, it can be seen that as one moves from Case 1 to Case 4, that is, in the cooling tube (200), the maximum deformation amount of the cooling channel (250) decreases as the number of cooling channels (250) increases. Specifically, as in Case 1 and Case 2, when the number of cooling channels (250) is provided in a total of 8 (specifically, 4 inlet channels and 4 outlet channels are provided each), it can be seen that the maximum deformation amount of the cooling channels (250) is greater than in Case 3 and Case 4, which are provided with a larger number than in Case 1 and Case 2. Meanwhile, when comparing Case 1 and Case 2, it can be seen that even when the number of cooling channels (250) is the same, a difference in the maximum deformation amount occurs depending on the spacing between each cooling channel (250).

[0099] When comparing Case 3 and Case 4, it can be seen that the maximum deformation amount of the cooling channels (250) in Case 3 (configuring 12 cooling channels with 6 inlet channels and 6 outlet channels each) and Case 4 (configuring 16 cooling channels with 8 inlet channels and 8 outlet channels each) is the same. In this case, it may be preferable to configure the cooling channels as in Case 3 rather than Case 4 in order to reduce pressure loss. Thus, the number of cooling channels (250) can be provided as a predetermined number that does not cause deformation while reducing pressure loss.

[0100] In the case of the cooling channel (250) according to one embodiment of the present invention, taking this into consideration, as previously described, the inlet channel (252) and outlet channel (256) may each be provided with 5, for a total of 10 channels.

[0101] Meanwhile, regarding the deformation of the cooling channel, the press speed during the press process did not have a significant effect even if the speed varied. In other words, regarding the flatness of the cell attachment surface of the cooling channel, the press speed during the press process has a small effect on the flatness.

[0102] These results highlight the importance of optimizing the number and arrangement of cooling channels to improve battery performance. Increasing the number of cooling channels distributes the cooling load more evenly, thereby reducing the maximum deformation that may occur during the pressing process. This not only improves the structural integrity of the cooling channels but also enhances the overall thermal management of the battery pack, which is necessary to maintain an optimal operating temperature and extend battery life.

[0103] Furthermore, the fact that the press speed has a negligible effect on the flatness of the cooling channels suggests that the manufacturer can minimize deformation by focusing on other variables, such as material properties and channel design. This can lead to the development of a more robust cooling system that is less sensitive to changes in the manufacturing process, thereby further improving the reliability and consistency of the battery pack production. For example, a configuration consisting of 10 cooling channels, comprising 5 inlet channels and 5 outlet channels, can provide a balanced cooling channel design approach that maximizes cooling efficiency while minimizing pressure loss and deformation. This configuration can be tailored to specific applications to ensure that each battery pack meets the unique performance requirements of various devices, ranging from consumer electronics to high-demand electric vehicles.

[0104]

[0105] FIG. 12 is a diagram illustrating the differential pressure per unit length according to the number of cooling channels of a cooling tube according to one embodiment of the present invention, and Table 1 below is a table showing the differential pressure for the flow rate according to the number of cooling channels of a cooling tube according to one embodiment of the present invention.

[0106] Pressure difference per unit length 0.5 1 1.5 2 Pressure difference per unit length (kPa / m) 5 ch (Arc) 3.1 6.6 7 10.4 0 14.2 8 6 ch (Arc) 3.4 17.3 8 11.5 9 16.1 9 7 ch (Arc) 4.4 49.6 0 15.0 8 20.8 7

[0107] Referring to Figure 12 and Table 1, the differential pressure results per unit length according to the number of channels of the cooling tube are illustrated. It can be seen that the differential pressure per unit length increases as the flow rate increases, and that the differential pressure increases as the number of cooling channels increases. Test results show that when the cooling channels are configured with 8 channels, the pressure loss increases by approximately 45% compared to when they are configured with 5 channels.

[0108] Meanwhile, in the test, the number of channels—5, 6, and 8—may refer to the individual number of inlet and outlet channels, rather than the total number of cooling channels. That is, in the case of 5 channels, it may mean a cooling tube composed of 5 inlet channels and 5 outlet channels, resulting in a total of 10 cooling channels. Similarly, in the case of 8 channels, it may mean a cooling tube composed of a total of 16 cooling channels. Ultimately, the test results indicate that reducing the number of cooling channels in the cooling tube can reduce pressure loss.

[0109] Therefore, according to the data from the above test, it can be seen that the differential pressure increases as the flow rate and number of the cooling channels increase. In particular, the pressure loss is approximately 45% higher in 8 channels compared to 5 channels. The test results indicate that the number of channels refers to both inlet and outlet channels, which implies that 5 channels correspond to a total of 10 cooling channels. Reducing the number of cooling channels effectively decreases pressure loss, thereby increasing the flow of the energy-efficient cooling medium. While more channels can improve heat dissipation, it is important to manage them to prevent excessive pressure loss, which is critical in applications such as electric and hybrid vehicles.

[0110] These test results emphasize the importance of balancing the number of cooling channels with the design to contribute to the development of better cooling solutions for high-performance battery packs.

[0111] FIG. 13 is a drawing for explaining the expected differential pressure according to the configuration of a battery cell array according to one embodiment of the present invention, and Table 2 below is a table showing the expected differential pressure according to the configuration of a battery cell array according to one embodiment of the present invention.

[0112] Flow Rate (LPM) 0.5 1 1.5 2 Differential Pressure (kPa) 24S10P_5ch 7.8 16.8 26.2 36 24S10P_8ch 11.2 24.2 38 52.6 35S14P_5ch 11.3 24.4 38.1 52.3 35S14P_8ch 16.3 35.2 55.2 76.5

[0113] Referring to Figure 13 and Table 2, the expected differential pressure results according to the battery cell array configuration are illustrated. It can be seen that the differential pressure increases as the flow rate increases, and that the differential pressure increases as the number of battery cells increases. Meanwhile, in Figures 9 and 10, only the flow path length of the cooling channel in the cooling tube was reflected, and the port and end plate portions connected to the external cooling device were not reflected. Accordingly, for example, in the case of a 24S10P array, the flow path length may be approximately 2520.4 mm (= 2 * 1260.2 mm), and in the case of a 35S14P array, the flow path length may be approximately 3663.3 mm (= 2 * 1831.7 mm).

[0114] Test results show that the differential pressure of the 8-channel configuration of the 24S10P array and the 5-channel configuration of the 35S14P array are nearly the same. In other words, when the cooling channels of the cooling tube are configured to 5 channels (5 inlet channels and 5 outlet channels each, for a total of 10 channels), more battery cells can be attached to the cooling tube. In other words, the cooling tube can be made longer, approximately 45% longer.

[0115] In this way, by configuring the number of cooling channels of the cooling tube to 5 channels each for the inlet and outlet channels, it is possible to design a cooling tube that allows for the attachment of more battery cells while relatively freely configuring the battery cell array.

[0116] Accordingly, Figure 13 and Table 2 show that the differential pressure increases with the flow rate and the number of battery cells. For example, the length of the cooling channels in the 24S10P array is approximately 2520.4 mm, while the length of the cooling channels in the 35S14P array is approximately 3663.3 mm. Although the 35S14P array is longer, the differential pressure is similar between the 8-channel configuration of the 24S10P array and the 5-channel configuration of the 35S14P array. This indicates that the 5-channel configuration (5 inlet channels and 5 outlet channels, a total of 10) allows for the use of more battery cells and longer cooling tubes for approximately 45% longer. This design can improve thermal management and overall performance by not only accommodating more battery cells but also providing flexibility in the battery cell array configuration.

[0117]

[0118] FIG. 14 is a schematic diagram illustrating a cooling channel of a cooling tube according to an embodiment of the present invention, Table 3 below is a table illustrating the number of channels and shape information of the cooling channel of the cooling tube of FIG. 14, Table 4 below is a table illustrating simulation results according to the number of channels and shape of the cooling channel according to an embodiment of the present invention, and Table 5 below is a table illustrating an analysis of the impact according to the simulation results of Table 4.

[0119] Dimension Item twh Quantity Shape 0.34 6.08 1.765 round

[0120]

[0121] No.twh Differential Pressure (kPa) Deformation Amount 10.346.081.85.710.40920.346.081.785.890.39130.346.081.766.080.37440.396.041.85.760.42250.396.041.785.940.40560. 396.041.766.120.38870.4461.85.80.42980.4461.785.980.41390.4461.766.170.397100.495.961.85.850.434110.495.961.786.030.418120.495. 961.766.230.401130.545.921.85.90.436140.545.921.786.090.421150.595.881.85.950.437160.595.881.786.140.422170.645.841.860.437180. 645.841.786.190.421190.695.81.86.060.435200.695.81.786.240.419210.745.761.86.110.433220.795.721.86.160.430230.845.681.86.220.426

[0122]

[0123] twh Differential Pressure (kPa) Deformation Amount t 1.000w - 1.000 1.000h 0.438 - 0.438 1.000 Differential Pressure (kPa) 0.573 - 0.573 - 0.485 1.000 Deformation Amount 0.658 - 0.658 0.836 - 0.134 1.000

[0124]

[0125] Referring to FIG. 14 and Tables 3 to 5, as previously discussed, it is important that no deformation occurs in the cell attachment surface (207) of the cooling channel (250) of the cooling tube (200) during the aforementioned press process of the cooling tube (200). Since deformation of the cell attachment surface (207) of the cooling tube (200) reduces the contact area between the cell attachment surface (207) and the battery cells (100), thereby reducing the heat transfer area and lowering the overall cooling performance, it is important to prevent this. Therefore, it is important to design the cell attachment surface (207) of the cooling tube (200) as a flat surface without deformation even during the press process.

[0126] During the above press process (see FIG. 10), the cell attachment surface (207) is pressed concavely and is relatively compressed, resulting in less deformation, while the cell non-attachment surface (209) is pressed convexly during the press process and is relatively elongated compared to the cell attachment surface (207), which may result in more deformation. Due to these concave and convex shapes, there is a high probability that deformation of the cooling channel (250), which is provided in a hollow shape within the cooling tube (200) between the cell attachment surface (207) and the cell non-attachment surface (209), will occur during the press process. Since the cooling channel (250), which is in a hollow shape for an internal flow path, is provided within the cooling tube (200), there is a high probability that deformation of the hollow cooling channel (250) will occur during the press process.

[0127] When the cooling channel (250) is deformed, the outer surface (207, 209) of the cooling tube (200), which is outside the cooling channel (250), may also be deformed together. For example, if deformation occurs such as the cooling channel (250) sinking to a predetermined depth, the outer surface (207, 209) of the cooling tube (200), that is, the cell attachment surface (207) and the cell non-attachment surface (209) of the cooling tube (200), may also sink to a predetermined depth by the amount of deformation of the cooling channel (250). Conversely, during the press process, deformation may occur in the inner surface (257, 259) of the cooling tube (200) due to the deformation of the cell attachment surface (207) and the cell non-attachment surface (209).

[0128] In particular, the deformation of the cell attachment surface (207) reduces the contact area with the battery cells (100), thereby lowering the heat transfer performance and acting as a factor in the reduction of cooling performance.

[0129] Meanwhile, in the case of the opposite side (209) of the cell attachment surface (207) of the cooling tube (200) in the cooling channel (250), since it is irrelevant to heat transfer performance, whether the opposite side (209) of the cell attachment surface (207) of the cooling tube (200) is deformed is relatively unimportant.

[0130] Therefore, it is necessary to design a cooling channel (250) that can minimize deformation of the cell attachment surface (207) in the cooling tube (200) and also reduce pressure loss.

[0131] First, as previously described, the cooling channel (250) may be provided with a total of 10 channels, with each of the inlet channel (252) and outlet channel (256) provided in 5 channels. In one embodiment of the present invention, the thickness (b) of the cooling tube (200) may be 2.5 mm. In the height direction of the cooling tube (200), the gap (c) between the inlet tube (252) and the outlet tube (256) that are closest to each other may be 4 mm. In the simulation, the thickness (b) of the cooling tube (200) and the gap (c) between the inlet tube (252) and the outlet tube (256) that are closest to each other may be fixed dimensions. Meanwhile, the compression distance through the press process may be 6.44 mm (initial 2.50 mm), and the preset differential pressure allowable range may be approximately 6.25 kPa.

[0132] Dimensional item t may refer to a predetermined spacing between cooling channels (250) in the height direction of the cooling tube (200). Specifically, dimensional item t may refer to a predetermined spacing between inlet channels (252) and a predetermined spacing between outlet channels (256) in the height direction of the cooling tube (200). Dimensional item w may refer to a length in the height direction of the cooling tube (200). Specifically, it may be the length (w) of each inlet channel (252) and each outlet channel (256) in the height direction of the cooling tube (200). Dimensional item h may refer to the width of the cooling channel (250) in the thickness (b) direction of the cooling tube (200). Specifically, it may be the width (h) of the cooling channel (250) in the stacking direction (X-axis direction) of the battery cells (100, see FIG. 1).

[0133] Referring to Table 4, it can be seen that the amount of deformation decreases as the dimension item h (the width of the cooling channel (250) in the direction of the thickness (b) of the cooling tube (200)) decreases. For example, as shown in No. 1 to No. 3, it can be seen that as the dimension item h decreases to 1.8 mm, 1.78 mm, and 1.76 mm, the amount of deformation also decreases in the order of 0.409, 0.391, and 0.374. Additionally, as shown in No. 4 to No. 6, it can be seen that as the dimension item h decreases to 1.8 mm, 1.78 mm, and 1.76 mm, the amount of deformation also decreases in the order of 0.422, 0.405, and 0.388. As the dimension item t (a predetermined spacing between each inlet channel (252) and each outlet channel (256) in the height direction of the cooling tube (200)) increases, the amount of deformation may increase. Additionally, it can be seen that as the dimension item w (the length of each inlet channel (252) and each outlet channel (256) in the height direction of the cooling tube (200)) decreases, the amount of deformation increases. When taken together, it can be seen that the result with the least amount of deformation within the differential pressure allowable range (6.25 kPa) is Case 3 of the simulation result according to No. 3.

[0134] Referring to Table 5, the influence of these dimensional items is analyzed as follows. First, the closer the value is to 1 in the table, the higher the influence between the two factors. It can be seen that the absolute value of the positive / negative difference between dimensional item t (a predetermined distance between cooling channels (250) in the height direction of the cooling tube (200)) and dimensional item w (length of each inlet channel (252) and each outlet channel (256) in the height direction of the cooling tube (200)) is the same under the conditions. This may mean that the absolute value of the influence is the same. As shown in the table, the factors that mainly have a large influence on the difference in deformation amount are dimensional item t (a predetermined distance between cooling channels (250) in the height direction of the cooling tube (200)) and dimensional item h, and it can be seen that dimensional item h has a relatively higher influence than dimensional item t.

[0135] Accordingly, the cooling channel (250) may preferably have a length (w) of 5.6 mm to 6.1 mm in the height direction of the cooling tube (200). Specifically, in the height direction of the cooling tube (200), each cooling tube (200) may have a length of 6.08 mm in the height direction of the cooling tube. More specifically, in the height direction of the cooling tube (200), the length (w) of each inlet channel (252) and each outlet channel (256) may be 6.08 mm.

[0136] Additionally, the predetermined spacing (t) between the cooling channels (250) in the height direction of the cooling tube (200) may be 0.3 mm to 0.9 mm. Specifically, the predetermined spacing (t) may be 0.34 mm in the height direction of the cooling tube (200). More specifically, in the height direction of the cooling tube (200), the predetermined spacing (t) between the inlet channels (252) and the predetermined spacing (t) between the outlet channels (256) may be 0.34 mm.

[0137] Meanwhile, ribs may be defined between adjacent channels in the cooling channels (250). For example, the thickness of the ribs may be 0.4 mm or less. Preferably, the thickness may be 0.34 mm. That is, the ribs may be a portion corresponding to a predetermined interval (t) between the cooling channels (250), and the thickness of each rib may be the minimum distance between adjacent channels.

[0138] In the direction of the thickness (b) of the cooling tube (200), the width (h) of the cooling channel (250) may be 1.7 mm to 1.8 mm. Specifically, in the stacking direction (X-axis direction) of the battery cells (100, see FIG. 1), the width (h) of the cooling channel (250) may be 1.7 mm to 1.8 mm. More specifically, the width (h) of the cooling channel (250) may be 1.76 mm in the stacking direction of the battery cells (100).

[0139] Additionally, the cooling channel (250) may have a rounded end in the height direction of the cooling tube (200). This cooling channel (250) may be defined as an elongated shape with curved top and bottom ends.

[0140] As such, as disclosed in Table 3, the cooling channel (250) according to one embodiment of the present invention may be formed to have a rounded end in the height direction of the cooling tube (200), a mutual spacing (t) of 0.34 mm in the height direction of the cooling tube (200), a length (w) of 6.08 mm in the height direction of the cooling tube (200), and a thickness (h) of 1.76 mm in the thickness direction (b).

[0141] In one embodiment of the present invention, a cooling tube (200) can be provided that minimizes deformation of the cooling channel near the cell attachment surface and the cell attachment surface through the cooling channel (250) provided with such shape, number, and number, while simultaneously significantly reducing pressure loss.

[0142] Accordingly, in one embodiment of the present invention, through a cooling tube (200) capable of securing heat transfer performance while minimizing pressure loss, the amount of energy consumed for cooling the battery cells (100) can be reduced, thereby enabling more efficient operation of the entire system.

[0143]

[0144] Referring again to FIGS. 1 and FIGS. 2, the battery cell array (10) may include a side structure unit (300).

[0145] The above-described side structure unit (300) supports the battery cells (100) and can secure the rigidity of the battery cells (100). The above-described side structure unit (300) is formed with a predetermined length along the longitudinal direction of the battery cell array (10) and is provided in one or more multiple units to be assembled together to accommodate and support the battery cells (100).

[0146] According to one embodiment of the present invention, the battery cell array (10) can form a cell array structure through the battery cells (100), the cooling tube (200), and the side structure unit (300). The side structure unit (300) forming the cell array structure can guide the formation of the battery cell array (10) without omitting a separate cover structure such as a conventional module frame, thereby implementing a so-called module frameless structure, which can make the battery cell array (10) slimmer and increase its energy density.

[0147] Referring again to FIG. 14 and Tables 3 through 5, it is shown that maintaining a flat cell attachment surface (207) during the press process is important to ensure optimal cooling performance. Deformation can reduce the contact area with the battery cell, thereby lowering heat transfer efficiency. Specifically, due to the hollow shape of the cooling channel (250), it is susceptible to deformation during compression, which affects the outer surface (207, 209) of the cooling tube (200). To minimize such deformation and reduce pressure loss, the design of the cooling channel is important. A configuration having five inlet channels and five outlet channels (a total of 10) and specific dimensions—such as a tube thickness of 2.5 mm, a spacing between adjacent tubes of 4 mm, and a compression distance of 6.44 mm—can help achieve this. Optimal dimensions for minimum deformation include a cooling channel width (h) of 1.76 mm, a length (w), and a spacing (t).

[0148] According to the simulation disclosed in this embodiment, it is shown that reducing the width (h) reduces deformation, and the spacing (t) between channels has a significant effect on deformation. These design parameters can ensure that the cooling tube maintains structural integrity and efficient thermal management.

[0149] In the battery cell array (10), the side structure unit (300) can support the battery cells and improve rigidity. This design can form a cell array structure without a separate module frame, thereby making the battery cell array slimmer and increasing energy density. The design of the cooling tube (200) can promote more efficient battery operation by minimizing pressure loss and energy consumption for cooling.

[0150]

[0151] FIG. 15 is a schematic plan view of a battery cell array for illustrating the arrangement of cooling tubes of a battery cell array according to one embodiment of the present invention, and FIG. 16 is an enlarged view of part E of FIG. 15.

[0152] Referring to FIGS. 15 and 16, in the battery cell array (10), the cooling tubes (200) may be arranged between the battery cells (100) arranged in two rows. Each cooling tube (200) may include a cell attachment surface (207) that is attached to the outer surface (105) of the battery cell (100) and is formed concavely, and a cell non-attachment surface (209) that is not attached to the outer surface of the battery cell (100) and is formed convexly.

[0153] The cell attachment surface (207) and the cell non-attachment surface (209) are formed alternately along the length direction (Y-axis direction) of the cooling tube (200) based on one side (+X-axis direction) or the other side (-X-axis direction) of the cooling tube (200), and may be formed in a zigzag position along the length direction (Y-axis direction) of the cooling channel (200) based on both sides (X-axis direction) of the cooling tube (200). That is, if one side (+X-axis direction) in the thickness direction (X-axis direction) of the cooling tube (200) is the cell attachment surface (207), the other side (-X-axis direction), which is opposite to the one side (+X-axis direction), may be the cell non-attachment surface (209).

[0154] The contact angle (θ) between the battery cells (100) and the cooling tube (200) can be approximately 60 degrees or an angle near thereto. The reason for setting the contact angle (θ) to be around 60 degrees is that if the contact angle (θ) is greater than 60 degrees, the cooling performance may be improved, but there is a problem that the size of the entire battery pack (1) must increase as the spacing between the battery cells (100) increases. In addition, as the contact angle increases, the curvature of the cooling tube (310) inevitably increases as well, so if the contact angle (θ) is much greater than 60 degrees, it may cause problems such as increased hydraulic pressure and poor cooling flow. Furthermore, if the contact angle (θ) is less than 60 degrees, there is a problem that the cooling efficiency decreases as the cooling surface area of ​​the battery cells (100) in contact with the cooling tube (200) becomes smaller.

[0155] Therefore, considering this, it is desirable that the contact angle (θ) be positioned within a range of approximately + / - 1.5 degrees based on 60 degrees. For example, the contact angle (θ) may be set within a range between 58.5 degrees and 61.5 degrees.

[0156] FIG. 17 is a schematic side cross-sectional view of a battery cell array to illustrate the arrangement of cooling tubes in the height direction of a battery cell array according to one embodiment of the present invention, and FIG. 18 is an enlarged view of part F of FIG. 17.

[0157] Referring to FIGS. 17, FIGS. 18, and the preceding FIGS. 16 and FIGS. 17, in the battery cell array (10), the cooling tube (200) can secure the cell attachment surface (257) as a flat surface according to the design of the cooling channel (250) described above, thereby increasing the degree of contact between the cell attachment surface (207) and the outer surface (105) of the battery cells (100), and also forming an internal flow path shape near the cell attachment surface (207) inside the cooling channel (250) without curvature, so that heat transfer performance can be maximized.

[0158] Meanwhile, the outer surface (105) of the battery cell (100) and the cell attachment surface (207) of the cooling tube (200) can be fixed in close contact with each other through an adhesive. The adhesive may be provided, for example, as a resin adhesive. In addition, it may be possible to provide a heat transfer pad having high adhesive strength between the outer surface (105) of the battery cell (100) and the cell attachment surface (207) of the cooling tube (200). Furthermore, it may be possible to form an adhesive strength by filling the space between the outer surface (105) of the battery cell (100) and the cell attachment surface (207) of the cooling tube (200) with a filling material made of resin.

[0159] FIGS. 19 and 20 are drawings for explaining the contact between a cooling tube and a battery cell when there is deformation of the cooling channel of a cooling tube according to an embodiment of the present invention.

[0160] Referring to FIG. 19, when deformation of the cooling tube (400) occurs due to deformation of the cooling channel (450) of the cooling tube (400), a predetermined space (S) is created between the cell attachment surface (407) of the cooling tube (400) and the outer surface (105) of the battery cell (100). The predetermined space (S) may refer to a non-contact space between the cooling tube (400) and the battery cell (100).

[0161] If such a predetermined space (S) occurs, the heat transfer performance of the cooling tube (400) is inevitably reduced by the amount of the reduced contact area. As previously discussed, such a predetermined space (S) can be caused by deformation of the cooling channel (450) during the press process of the cooling tube (400), particularly deformation of the cooling channel (450) positioned near the cell attachment surface (407) of the cooling tube (400). In this way, deformation of the cooling channel (450) positioned near the cell attachment surface (407) and the resulting deformation of the cell attachment surface (407) of the cooling tube (400) can cause a decrease in the cooling performance of the cooling tube (400).

[0162] Referring to FIG. 20, the cooling tube (500) according to the present embodiment may be formed to have a flat surface only on the side of the cell attachment surface (507) and the inner surface (557) close to the cell attachment surface (507), and to have a certain curvature on the side of the cell non-attachment surface (509) and the inner surface (559) relatively far from the cell attachment surface (507). In other words, in the present embodiment, the cell attachment surface (507) and the inner surface (557) of the cooling channel (550) close thereto have a flat surface, and the cell non-attachment surface (509) and the inner surface (559) of the cooling channel (550) close thereto have a non-flat surface. That is, the cell non-attachment surface (509), which is provided on the opposite side of the cell attachment surface (507) of the cooling tube (500) and does not come into contact with the outer surface (105) of the battery cells (100), can be provided as a non-flat surface with greater deformation than the flat surface of the cell attachment surface (507).

[0163] As previously described, the cell attachment surface (507) is pressed concavely during the press process (see FIG. 5) and is relatively compressed, resulting in less deformation, while the cell non-attachment surface (509) is pressed convexly during the press process (see FIG. 10) and is relatively elongated compared to the cell attachment surface (207), which may result in more deformation. In this embodiment, the cell attachment surface (507) that contacts the outer surface (105) of the battery cells (100) is formed as a flat surface, and the cell non-attachment surface (507) that does not contact the outer surface (105) of the battery cells (100) may be formed as a non-flat surface having a greater degree of deformation compared to the cell attachment surface (507), which is a flat surface.

[0164] The cell attachment surface (507) having the flat surface and the cell non-attachment surface (509) having the non-flat surface are formed alternately along the length direction (Y-axis direction, see FIG. 15) of the cooling tube (500) based on one side (+X-axis direction) or the other side (-X-axis direction) of the cooling tube (500), and can be formed in a zigzag position along the length direction (Y-axis direction, see FIG. 15) of the cooling channel (500) based on both sides (X-axis direction) of the cooling tube (500). That is, in this embodiment, the flat surface and the non-flat surface are formed alternately along the length direction (Y-axis direction, see FIG. 15) of the cooling tube (500) based on one side (+X-axis direction) or the other side (-X-axis direction) of the cooling tube (500), and can be formed in a zigzag position along the length direction (Y-axis direction, see FIG. 15) of the cooling channel (500) based on both sides (X-axis direction) of the cooling tube (500).

[0165] In the case of the cell non-attachment surface (509) provided as a non-flat surface, it does not come into contact with the battery cell (100), so unlike the cell attachment surface (507), flatness is relatively less important. Therefore, as in this embodiment, the cooling channel (550) can be designed by considering only the prevention of deformation of the cell attachment surface (507) and the cooling channel (550) near the cell attachment surface (507) so as to secure flatness near the cell attachment surface (507). Thus, in this embodiment, even if the cell non-attachment surface (509) that does not come into contact with the battery cells (100) is formed as a non-flat surface, the cell attachment surface (507) that comes into contact with the outer surface (105) of the battery cells (100) is formed as a flat surface, so that contact performance between the battery cells (100) and the cooling tube (500) can be secured. Accordingly, in this embodiment, the cooling tube (500) can be designed by considering only the flatness of the attachment surface with the battery cells (100) during the press process of the cooling tube (500), thereby securing a relatively greater degree of design freedom for the cooling tube (500).

[0166] In the present embodiment, as a method for configuring cooling tubes used in a battery pack, the goal may be to optimize cooling efficiency by minimizing pressure loss and deformation. This method may begin by ensuring a uniform cooling distribution by extending a cooling tube, designed to be characterized by length, width, and height dimensions to facilitate the flow of the cooling medium, along its entire length. The next step may be to change both the number of channels (N) and the aspect ratio (D) of each channel. The aspect ratio D may be related to the geometric ratio of the channels, which directly affects the flow dynamics and heat transfer capacity of the cooling system. An important part of this method may be to determine the pressure drop ΔP across the entire cooling tube for each change in the number of channels N and the aspect ratio D. This pressure drop ΔP can be calculated using the equation ΔP = f (N, D, L, T), where L is the length of the cooling tube and T is the thickness of the rib separating adjacent channels. This evaluation may be necessary to understand how various configurations affect the resistance to the cooling medium flow, which is essential for maintaining efficient cooling performance. This method may also include a step of determining the deformation δ of each channel when the cooling tube is bent to fit the battery array of the battery pack. Here, the deformation δ can be evaluated using the equation δ = f (N, D, T) as a mathematical formula.

[0167] This analysis can ensure that the cooling tube maintains structural integrity and does not compromise the contact area required for effective cooling. Additionally, this method may involve determining the optimal relationship between the number of channels N, the aspect ratio D, and the rib thickness T factors regarding pressure drop ΔP and deformation δ. The goal of this method is to maximize the cooling efficiency of the defined cooling tube by minimizing both pressure loss and deformation, thereby enabling the cooling system to operate effectively under various thermal loads and mechanical stresses. By systematically analyzing and adjusting these parameters, this method can provide a method for designing cooling tubes that provide enhanced performance for battery packs, particularly in applications where efficient thermal management is critical.

[0168]

[0169] FIG. 21 is a schematic diagram illustrating a battery cell array according to another embodiment of the present invention.

[0170] Since the battery cell array (20) according to the present embodiment is similar to the battery cell array (10) of the preceding embodiment, redundant descriptions of configurations that are substantially identical or similar to the preceding embodiment are omitted, and the following focuses on the differences from the preceding embodiment.

[0171] Referring to FIG. 21, the battery cell array (20) may include the cooling tube (500) and the battery cell (120).

[0172] The battery cell (120) may be provided as a prismatic secondary battery. The battery cell (120) may be provided as one or more multiple units. In this way, the cooling tube (500) may also be applied to the battery cell array (20) in which the battery cell (120) is provided as a prismatic secondary battery (120). As in the previous embodiment, even if the cell non-attachment surface (509) that does not come into contact with the battery cell (120) is formed as a non-flat surface, the cell attachment surface (507) that comes into contact with the outer surface (125) of the battery cell (120) is formed as a flat surface, thereby ensuring contact performance between the battery cell (120) and the cooling tube (500). Therefore, even in the battery cell array (20) in which the battery cell (120) as in the present embodiment is provided as a prismatic secondary battery (120), the cooling tube (500) can be designed by considering only the flatness of the attachment surface with the battery cell (120) during the press process of the cooling tube (500), thereby securing a relatively greater degree of design freedom for the cooling tube (500).

[0173] Accordingly, according to the present embodiment, even in the battery cell array (20) having a battery cell (120) type equipped with the prismatic secondary battery (120), a cooling tube (500) structure capable of securing heat transfer performance and minimizing pressure loss can be implemented. In addition, it is obvious that the battery cell array (20) may include the aforementioned cooling tubes (200, 201, 202, 203) depending on the design.

[0174] FIG. 22 is a drawing for illustrating a battery cell array according to another embodiment of the present invention.

[0175] Since the battery cell array (30) according to the present embodiment is similar to the battery cell array (10) of the preceding embodiment, redundant descriptions of configurations that are substantially identical or similar to the preceding embodiment are omitted, and the following focuses on the differences from the preceding embodiment.

[0176] Referring to FIG. 22, the battery cell array (30) may include the cooling tube (500) and the battery cell (130).

[0177] The battery cell (130) may be provided as a pouch-type secondary battery. The battery cell (130) may be provided as one or more multiple units. In this way, the cooling tube (500) may also be applied to the battery cell array (30) in which the battery cell (130) is provided as a pouch-type secondary battery (130). As in the previous embodiment, even if the cell non-attachment surface (509) that does not come into contact with the battery cell (130) is formed as a non-flat surface, the cell attachment surface (507) that comes into contact with the outer surface (135) of the battery cell (130) is formed as a flat surface, thereby ensuring contact performance between the battery cell (130) and the cooling tube (500). Therefore, even in the battery cell array (30) in which the battery cell (130) as in the present embodiment is provided as a pouch-type secondary battery (130), the cooling tube (500) can be designed by considering only the flatness of the attachment surface with the battery cell (130) during the press process of the cooling tube (500), thereby securing a relatively greater degree of design freedom for the cooling tube (500).

[0178] Accordingly, according to the present embodiment, even in the battery cell array (30) having a battery cell (130) type equipped with the pouch-type secondary battery (130), a cooling tube (500) structure capable of securing heat transfer performance and minimizing pressure loss can be implemented. In addition, depending on the design, the battery cell array (30) may also include the aforementioned cooling tubes (200, 201, 202, 203).

[0179] In this way, the design structure of the cooling tube (200, 201, 202, 203, 500) according to the present embodiment can be applied to all of the cylindrical secondary battery (100), the prismatic secondary battery (120), and the pouch-type secondary battery (130).

[0180] Accordingly, according to the present embodiment, a cooling tube (200, 201, 202, 203, 500) can be configured and provided to secure heat transfer performance and minimize pressure loss in all of the cylindrical secondary battery (100), the prismatic secondary battery (120), and the pouch-type secondary battery (130).

[0181]

[0182] FIG. 23 is a drawing for explaining a battery pack according to an embodiment of the present invention, and FIG. 24 is a drawing for explaining a vehicle according to an embodiment of the present invention.

[0183] Referring to FIGS. 23 and 24, the battery pack (1) according to one embodiment of the present invention may include at least one battery cell array (10, 20, 30) according to a prior embodiment and a pack case (50) that accommodates the battery cell array (10, 20, 30).

[0184] The above battery pack (1) may further include electrical components such as a BMS that controls the battery cell array (10, 20, 30) or a cooling unit such as a heat sink for cooling the battery cell array (10, 20, 30).

[0185] A battery pack (1) according to one embodiment of the present invention may further include various other components of a battery pack (1) known at the time of filing the present invention. For example, a battery pack (1) according to one embodiment of the present invention may further include components such as a current sensor, a fuse, and a service plug.

[0186] In addition, a vehicle (V) according to one embodiment of the present invention may include one or more battery packs (1) according to the present invention. A vehicle (V) according to one embodiment of the present invention may further include various other components included in the vehicle in addition to the battery pack (1). For example, a vehicle (V) according to one embodiment of the present invention may further include, in addition to the battery pack (1) according to one embodiment of the present invention, a vehicle body, a motor, an ECU (electronic control unit), or a control device.

[0187] In addition, it is obvious that the battery pack (1) according to one embodiment of the present invention may also be provided in other devices, mechanisms, and facilities, such as an energy storage system using a secondary battery, in addition to the vehicle (V).

[0188] According to various embodiments as described above, a battery cell array (10, 20, 30) equipped with a cooling tube (200) capable of securing heat transfer performance and minimizing pressure loss, a battery pack (1) including the same, and a vehicle (V) can be provided.

[0189] In addition, the present invention may disclose a cooling tube designed for use in a battery pack. The cooling tube may include a plurality of channels configured to allow a cooling medium to pass through. Each channel of the cooling tube may have an aspect ratio defined by its height and width. The cooling tube may be designed to bend to fit a first linear battery arrangement of the battery pack, thereby ensuring that a first side of the cooling tube contacts a battery cell. The configuration of the number of channels and the aspect ratio of each channel may be specifically designed to maximize the cooling efficiency of the cooling tube. This can be achieved by minimizing the number of channels to reduce pressure drop caused by the cooling medium and by minimizing deformation of the channels during the bending process.

[0190] According to the various embodiments described above, a method for configuring a cooling tube of a battery pack capable of securing heat transfer performance and minimizing pressure loss, and a cooling tube of a battery pack can be provided.

[0191]

[0192] As described above, although the present invention has been explained by limited embodiments and drawings, the present invention is not limited thereto, and it is obvious that various modifications and variations are possible within the scope of the technical spirit of the present invention and the equivalent scope of the claims described below by those skilled in the art to which the present invention belongs.

Claims

1. A method for configuring the cooling tubes of a battery pack, A cooling tube having a plurality of channels through which a cooling medium can pass, wherein the cooling tube defines a length, width, and height, and each channel extends across the length of the cooling tube; A step of changing the number of channels N and the aspect ratio D of the channels in the cooling tube; A step of determining a pressure drop ΔP across the cooling tube for a change in the number of channels N and the aspect ratio D of the channels using the mathematical formula ΔP = f (N, D, L, T), where L is the length of the cooling tube and T is the thickness of the rib separating adjacent channels; A step of determining the deformation δ of each channel when the cooling tube is bent to fit the arrangement of battery cells of the battery pack with respect to changes in the number of channels N and the aspect ratio D of the channels using the mathematical formula δ = f (N, D, T); and A step of determining the relationship between the number of channels N, the aspect ratio D of the channels, and the thickness T of the rib by referring to the pressure drop ΔP and deformation δ so as to maximize the cooling efficiency of the cooling tube. Includes, A method for configuring a cooling tube of a battery pack, characterized in that the above cooling efficiency is associated with minimizing pressure loss and minimizing deformation.

2. In Paragraph 1, A method for configuring cooling tubes of a battery pack, characterized in that the aspect ratio D of each channel is defined by the height and width of each channel.

3. In Paragraph 1, A method for configuring cooling tubes of a battery pack, characterized in that each channel is defined as having an elongated shape with curved top and bottom ends.

4. In Paragraph 3, A method for configuring a cooling tube of a battery pack, characterized in that the thickness of each rib T is the minimum distance between adjacent channels.

5. In Paragraph 1, The step of bending the cooling tube above is, A method for configuring a cooling tube of a battery pack, characterized by including the step of bending the cooling tube to fit the shape of a first linear array of battery cells of the battery pack.

6. In Paragraph 5, A method for configuring a cooling tube of a battery pack, characterized in that the cooling tube above contacts each battery cell of the first preceding array.

7. In Paragraph 6, The above cooling tube is configured to be positioned between the first linear array of battery cells of the battery pack and the second linear array of battery cells, and The first surface of the cooling tube is in contact with the first linear array, and A method for configuring a cooling tube of a battery pack, characterized in that the second surface of the cooling tube is in contact with the second linear array.

8. In Paragraph 1, The step of determining the pressure drop ΔP above is, A method for configuring a cooling tube of a battery pack, characterized by including the step of determining the pressure drop ΔP across the cooling tube for each change in the number of channels N and the aspect ratio D of the channels based on the viscosity and flow rate of the cooling medium.

9. In Paragraph 1, The step of determining the relationship between the above factors is, A method for configuring a cooling tube of a battery pack, characterized by including the step of determining the relationship between the number of channels N, the aspect ratio D of the channels, the pressure drop ΔP, and the deformation δ using correlation analysis.

10. In Paragraph 1, The above plurality of channels are, A first channel set and a second channel set, wherein the first channel set allows the inflow of the cooling medium into the cooling tube and the second channel set allows the outflow of the cooling medium from the cooling tube. A method for configuring a cooling tube of a battery pack characterized by including 11. In Paragraph 10, The cooling tube is configured to include five or fewer channels for each of the first channel set and the second channel set, and The aspect ratio of each channel is 3.45 or less, and A method for configuring a cooling tube of a battery pack, characterized in that the thickness of the above rib is 0.34 mm or less.

12. In Paragraph 11, A method for configuring a cooling tube of a battery pack, characterized in that the pressure ΔP per unit length of each channel is 6.67 kPa / m or less for a cooling medium flow rate of 1 liter / min.

13. In the cooling tube of a battery pack, A plurality of channels configured to allow a cooling medium to flow through the cooling tube, wherein each channel comprises the plurality of channels having an aspect ratio defined by height and width, The above cooling tube is bent to correspond to the first linear array of the battery pack such that the first side of the cooling tube contacts the first linear array of the battery cells, and A cooling tube of a battery pack, characterized in that the plurality of channels and the aspect ratio of each channel are configured to maximize the cooling efficiency of the cooling tube by minimizing the pressure drop of the cooling medium and minimizing channel deformation that occurs when the cooling tube is bent.

14. In Paragraph 13, The above plurality of channels are, A first set of channels for the inflow of the above cooling medium; and A second channel set for the outflow of the above cooling medium A cooling tube of a battery pack characterized by including 15. In Paragraph 14, The first channel set is provided between 4 and 6 channels, and The cooling tube of a battery pack, characterized in that the second channel set is provided between 4 to 6 channels.

16. In Paragraph 15, The above-mentioned first channel set has five channels, and The above second channel set is a cooling tube of a battery pack characterized by having five channels.

17. In Paragraph 16, A cooling tube of a battery pack characterized in that the aspect ratio of each of the first channel set and the second channel set is 4 or less.

18. In Paragraph 17, A cooling tube of a battery pack characterized in that the aspect ratio of each of the first channel set and the second channel set is 3.

45.

19. In Paragraph 14, A cooling tube of a battery pack characterized by ribs defined between adjacent channels.

20. In Paragraph 19, A cooling tube for a battery pack, characterized in that the thickness of the above-mentioned rib is 0.4 mm or less.

21. In Paragraph 20, A cooling tube for a battery pack characterized by having a thickness of 0.34 mm.

22. In Paragraph 19, A cooling tube of a battery pack, characterized in that each channel is defined as having an elongated shape with curved top and bottom ends.