Battery Cooling Frame With Contact Plate for Higher Energy Density
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Solution Overview
Problem
Existing battery cooling systems are inefficient in managing heat generated during electrical energy storage and transmission, often relying on natural convection and requiring additional cooling structures to prevent heat damage.
Innovation Solution
An integrated battery cooling module with a frame that encloses the battery stack and includes a cooling plate, either with cooling fins or channels, bonded to the frame and in physical contact with the battery stack, enhancing thermal conduction and allowing for interchangeable air- or liquid-cooling configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If natural convection is used for heat dissipation, then the cooling structure is simple, but the cooling capacity is insufficient when heat generated is great
Solution Approach 1:
The cooling plate is integrated with the frame structure, merging the support function and cooling function into a single component. This reduces overall system complexity while providing active cooling capability through the integrated structure that combines structural support with thermal management.
Solution Approach 2:
The cooling plate serves multiple functions: it provides structural reinforcement to the frame, acts as a heat dissipation component through its contact with battery terminals, and offers mounting surfaces for additional cooling components. This multi-functionality addresses both structural and thermal management requirements simultaneously.
2Reliability
If additional cooling structures are added to prevent heat damage, then the cooling capacity is improved, but the volume and weight of the battery module increase
Solution Approach 1:
By integrating the cooling plate with the frame structure, the patent eliminates the need for separate cooling components, thereby reducing overall module volume and weight while maintaining effective cooling capacity through the combined structural-thermal management system.
Solution Approach 2:
The cooling plate performs multiple functions including structural support and active cooling, which reduces the need for additional dedicated cooling components and minimizes the overall volume and weight of the battery module while ensuring adequate thermal management.
3Reliability
If additional cooling structures are added to prevent heat damage, then the cooling capacity is improved, but the weight of the battery module increases
Solution Approach 1:
The integration of the cooling plate with the frame structure eliminates redundant components, reducing overall system weight while maintaining cooling capacity through the multi-functional integrated design that combines structural support with thermal management.
Solution Approach 2:
The cooling plate serves dual purposes as both a structural reinforcement element and a cooling component, which reduces the need for separate cooling hardware and thereby decreases the overall weight of the battery module while ensuring adequate cooling performance.
4Quantity of substance
If cooling plates are integrated with the frame, then the energy density is improved, but the manufacturing complexity increases
Solution Approach 1:
By integrating the cooling plate with the frame, the patent reduces the total component count and assembly steps, which can actually simplify manufacturing despite the integrated design. The unified structure requires fewer separate parts to be manufactured and assembled, potentially reducing overall manufacturing complexity.
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 integrated cooling module improves thermal conduction and reduces the overall volume and weight of the battery module, increasing energy density and providing better cooling capacity compared to traditional designs, while allowing for easy replacement and installation of different cooling plates.
Implementation Method 1
enhancing thermal conduction and allowing for interchangeable air- or liquid-cooling configurations
Implementation Method 2
the first and second cooling plates each include a plurality of cooling fins
Implementation Method 3
the first and second cooling plates each include cooling channels for circulating liquid
Data Source
AI summary
An integrated battery cooling module including a battery stack having a top end, a front end, a bottom end separated from the top end by a height of the front end, a back end separated from the front end by a length of the top end. The integrated battery cooling module also includes a frame at least partially enclosing the battery stack on the front end and the back end, the frame compressing the battery stack between the front end and the back end. Further, the integrated battery cooling module includes a cooling plate bonded to and structurally reinforcing the frame and in physical contact with one of the top end and the bottom end of the battery stack.