Battery Module Cooling Fin With Fluid Conduits for Cell Temperature Control
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Solution Overview
Problem
Typical air-cooled battery packs struggle to maintain battery cells within a desired temperature range due to ambient air temperatures often exceeding the maximum operating temperature of the cells.
Innovation Solution
A battery module design incorporating a cooling fin with a panel portion and rail portions of greater thickness, featuring apertures for conduits that receive refrigerant or coolant to efficiently conduct heat energy away from the battery cells, along with a condenser, compressor, and heat exchanger system to regulate temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air-cooling is used for battery cells, then the cooling system is simple, but the battery cells cannot be maintained within desired temperature range when ambient air temperature exceeds maximum operating temperature
Solution Approach 1:
The patent introduces a cooling fluid as an intermediary substance between the battery cells and the ambient environment. The cooling fluid absorbs heat from the battery cells through thermal conduction and transports it to a heat exchanger, where heat is transferred to ambient air. This mediator approach resolves the contradiction by enabling effective heat removal even when ambient air temperature exceeds battery operating limits.
Solution Approach 2:
The patent replaces direct air-to-cell convection cooling with a fluid-based thermal conduction system. Instead of relying on ambient air flow directly across battery cells, the system uses a circulating cooling fluid that conducts heat away from the cells through controlled thermal pathways, substituting the mechanical convection process with a more controllable conduction-based system.
2Loss of energy
If cooling fins are added to conduct heat away from battery cells, then heat transfer efficiency improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extends the cooling fins in multiple directions to create a three-dimensional heat dissipation structure. The fins project from the battery cell housing in various orientations, increasing the surface area available for heat transfer to the cooling fluid. This multi-dimensional arrangement maximizes thermal contact between the cooling fluid and battery surfaces without requiring excessive structural complexity.
Solution Approach 2:
The cooling fin structure serves multiple functions simultaneously: it acts as a thermal conduction pathway from battery cells to cooling fluid, provides structural support for the cooling system, and creates flow channels for the cooling fluid. This multi-functionality reduces overall system complexity by combining several components into one integrated structure.
3Strength
If cooling fins with greater thickness are used, then heat conduction capability improves, but manufacturing precision requirements and device complexity increase
Solution Approach 1:
The patent employs composite material construction for the cooling fins, combining materials with high thermal conductivity with structurally sound materials. This allows the fins to achieve the necessary heat conduction capability through material properties rather than solely relying on increased thickness, thereby reducing manufacturing precision requirements and overall device 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
Effectively maintains battery cells within a desired temperature range (15°-35°C) by efficiently conducting heat energy from the cells to the cooling medium, ensuring reliable operation and extending the battery's lifespan.
Implementation Method 1
The first cooling fin conducts heat energy from the first battery cell into the first cooling fin to cool the first battery cell
Implementation Method 2
The first and second conduits extend through the apertures of the first and second rail portions constructed from the folded portions, respectively, of the first cooling fin and receive a fluid that flows through the first and second conduits to conduct heat energy from the first cooling fin into the fluid
Implementation Method 3
The condenser is configured to receive the refrigerant from the first and second conduits of the battery module and to extract heat energy from the refrigerant
Implementation Method 4
The compressor is configured to pump the refrigerant from the condenser into the first and second conduits
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Battery systems, battery modules, and a method for cooling a battery module are provided. The battery module includes a first battery cell, and a first cooling fin having a first panel portion and first and second rail portions that are disposed on first and second ends, respectively, of the first panel portion. The first battery cell is disposed adjacent to a first side of the first panel portion. The first and second rail portions have a thickness greater than the first panel portion. The first cooling fin conducts heat energy from the first battery cell into the first cooling fin to cool the first battery cell. The battery module further includes first and second conduits extending through the first and second rail portions, respectively, that receive a fluid that flows through the first and second conduits to conduct heat energy from the first cooling fin into the fluid.