Cylindrical Battery Cell Thermal Conduction via Modular Receptacles
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Solution Overview
Problem
Cylindrical battery cells, despite their high energy density and low cost, are challenging to cool efficiently and cost-effectively in large battery systems for electric vehicles due to their shape, making it difficult to maintain ideal operating conditions.
Innovation Solution
A modular battery unit design featuring pairs of oppositely disposed receptacles with one end for electrical connection and the other for thermal conduction, using a thermally conductive second end wall and a cooling plate to dissipate heat, along with an integrated battery management system for efficient cooling and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cylindrical battery cells are used to achieve high energy density and low cost, then energy density and manufacturing cost are improved, but cooling efficiency deteriorates due to the cylindrical shape making it difficult to maintain ideal operating conditions
Solution Approach 1:
The battery system is divided into modular battery units, each containing a specific number of cylindrical battery cells arranged in chambers. This segmentation allows for standardized cooling modules to be applied to each unit, making the cooling system more manageable and efficient while maintaining the high energy density benefits of cylindrical cells.
Solution Approach 2:
Thermal conduction members (heat sinks) are introduced as intermediary components between the cylindrical battery cells and the cooling system. These members facilitate heat transfer from the cells to the cooling plate, solving the cooling efficiency problem while preserving the cylindrical cell configuration and its associated energy density advantages.
2Power
If hundreds to thousands of cylindrical cells are bundled into a large battery system to provide required power, then power output is improved, but temperature regulation complexity and cost increase
Solution Approach 1:
The large battery system is segmented into multiple identical battery units, each with its own integrated cooling module. This modular approach simplifies temperature regulation by standardizing the cooling solution across all units, reducing overall system complexity while maintaining high power output through parallel configuration.
Solution Approach 2:
The cooling function is merged with the structural housing of each battery unit, creating an integrated cooling module. This combination eliminates the need for separate cooling systems for each cell or small group of cells, thereby reducing complexity and cost while scaling to accommodate hundreds or thousands of cells.
3Temperature
If cylindrical battery cells are cooled by placing them directly adjacent to a cooling plate, then cooling effectiveness is improved, but manufacturing complexity and assembly cost increase
Solution Approach 1:
The cooling system is segmented into standardized modules that can be independently manufactured and then assembled with battery cell groups. This modular design simplifies manufacturing by allowing parallel production of cooling modules and battery assemblies, reducing overall manufacturing complexity while maintaining effective cooling.
Solution Approach 2:
Thermal conduction members are used as intermediary components that simplify the interface between cylindrical cells and the cooling plate. These standardized intermediaries facilitate heat transfer while providing a uniform mounting interface, thereby reducing manufacturing complexity and assembly difficulty compared to direct cell-to-plate contact.
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 design allows for efficient cooling and cost-effective assembly of battery units, maintaining optimal temperature and enabling scalable battery modules with varying output voltages and powers, enhancing the performance and reliability of electric vehicle batteries.
Implementation Method 1
the second end wall forming a thermal conduction path for dissipating heat
Data Source
AI summary
The present invention relates to a battery unit comprising one or more pairs of oppositely disposed receptacles, each said pair of receptacles defining a respective chamber for accommodating one or more cylindrical battery cells, each cylindrical battery cell having a first end adjacent a first end wall of a first one of said receptacles and a second end adjacent a second end wall of a second one of the pair of said receptacles. The invention further relates to a battery module comprising one or more battery units and to a battery system comprising a plurality of battery modules.