Battery Module Cooling Pipe Layout for Leak-Safe Multi-Plane Joining
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Solution Overview
Problem
Battery modules for high-power applications like electric vehicles face challenges in output and capacity, requiring multiple batteries connected in a module, which can lead to issues such as water leakage and reduced lifespan due to complex cooling systems.
Innovation Solution
A battery module design featuring cooling pipes on different planes connected through a simple and sealed structure using inclined connection units and a connection member, preventing water leakage and enhancing module longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple batteries are connected in a battery module to increase output and capacity, then the power output and energy capacity are improved, but the complexity of the cooling system increases and water leakage risk rises
Solution Approach 1:
The cooling system is segmented into multiple cooling pipes arranged in parallel, with each pipe serving a specific battery or group of batteries. This segmentation allows for simplified individual pipe designs while achieving comprehensive cooling coverage across the entire battery module, thereby increasing power output without proportionally increasing system complexity.
Solution Approach 2:
The branch unit is designed with a nested structure where the connection member integrates multiple connection functions. The lower connection pipe and upper connection pipe are nested within the connection member, creating a compact multi-functional component that reduces overall system complexity while maintaining the required cooling capacity for high-power battery modules.
2Temperature
If cooling pipes are arranged on different planes to improve heat dissipation efficiency, then the cooling effectiveness is improved, but the connection complexity and water leakage risk increase
Solution Approach 1:
Cooling pipes are arranged on different planes (first plane and second plane) to improve heat dissipation efficiency by accessing heat sources from multiple spatial dimensions. The branch unit bridges these different planes through a standardized connection member, maintaining reliability by providing sealed connections across the dimensional transition.
Solution Approach 2:
The connection member acts as an intermediary component between cooling pipes on different planes. It provides a standardized interface that ensures reliable sealing and connection, thereby maintaining system reliability while enabling the multi-plane arrangement that improves heat dissipation efficiency.
3Productivity
If a complex cooling system is used to handle heat from multiple batteries, then the heat dissipation capability is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The connection member is designed as a universal component that performs multiple functions: connecting cooling pipes on different planes, providing sealing, and facilitating assembly. This multi-functionality maintains high heat dissipation capability while simplifying manufacturing and assembly processes, as the same connection member can be used throughout the battery module.
Solution Approach 2:
The branch unit is pre-assembled with the connection member integrated before installation into the battery module. This preliminary assembly simplifies the overall manufacturing process by reducing the number of steps required during final module assembly, thereby maintaining high heat dissipation capability while improving ease of manufacture.
Data Source
AI summary
Provided is a battery module. The battery module includes: a first cooling pipe; a second cooling pipe connected to the first cooling pipe and arranged on a different plane than the first cooling pipe; and a branch unit connecting the first cooling pipe and second cooling pipe, wherein the branch unit includes: a lower connection pipe connected to the first cooling pipe; an upper connection pipe connected to the second cooling pipe; and a connection member into which one of the lower connection pipe and the upper connection pipe is inserted and which is inserted into the other one of the lower connection pipe and the upper connection pipe.