Battery Module Cooling Plate Layout for Lighter Expandable Packs
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Solution Overview
Problem
Conventional battery modules with expandable structures are complicated, heavy, and have inefficient cooling systems, necessitating separate insulating covers and end plates that increase weight and production complexity.
Innovation Solution
A battery module design featuring integrated cooling plates with parallel refrigerant flow paths, eliminating the need for separate insulating covers and end plates, and incorporating a unified upper plate to simplify structure and enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating covers and end plates are provided for each battery cell stack in expandable battery module structure, then electrical insulation and physical protection are ensured, but the weight of the battery module increases and the structure becomes complicated
Solution Approach 1:
The patent merges the insulating cover and end plate into a single integrated component called a 'busbar frame'. This busbar frame simultaneously provides electrical insulation (through insulating material coverage) and physical protection (through structural rigidity), eliminating the need for separate insulating covers and end plates for each battery cell stack. The integration reduces structural complexity while maintaining both electrical insulation and mechanical protection functions.
Solution Approach 2:
The busbar frame is designed as a multi-functional component that serves multiple purposes: it provides electrical insulation, physical protection, structural support, and serves as a mounting structure for busbars. This universal component replaces multiple specialized parts (insulating cover, end plate, busbar mounting structure), simplifying the overall battery module structure while ensuring reliable electrical insulation and physical protection.
2Reliability
If separate insulating covers and end plates are provided for each battery cell stack, then electrical insulation and physical protection are ensured, but the production process is lengthened
Solution Approach 1:
By combining the insulating cover and end plate into a single integrated busbar frame component, the number of assembly steps is reduced. Instead of separately attaching insulating covers and end plates to each battery cell stack, the integrated busbar frame can be installed as a single unit, streamlining the production process and improving manufacturing efficiency while maintaining electrical insulation and physical protection.
Solution Approach 2:
The busbar frame is designed and pre-assembled with insulating materials and busbar mounting structures integrated before installation. This preliminary integration of multiple functions into a single component allows for faster on-site assembly during production, reducing the overall manufacturing time and improving productivity while ensuring proper electrical insulation and physical protection are already in place.
3Reliability
If conventional end plate and insulating cover structure is used in expandable battery module, then physical protection is provided, but the weight of the battery module increases
Solution Approach 1:
The integration of insulating cover and end plate into a single busbar frame eliminates redundant materials and structural elements. By combining these components, the total material usage is reduced, leading to weight reduction while maintaining the physical protection function. The integrated design allows for optimized material distribution and elimination of overlapping structures that would add unnecessary weight.
Solution Approach 2:
The patent extracts and eliminates redundant components from the conventional design. By removing the separate insulating cover and standalone end plate structures, only the essential protective functions are retained within the integrated busbar frame. This extraction of unnecessary components reduces the overall weight of the battery module while preserving the required physical protection capabilities.
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
Reduces weight, simplifies assembly, lowers production costs, and improves cooling performance by integrating cooling and reducing pressure loss, while allowing for expandable battery pack configurations.
Implementation Method 1
a cooling plate arranged below the bottom portion of the module frame, wherein a flow path through which refrigerant flows is formed in the cooling plate
Implementation Method 2
the flow path is formed in a direction parallel to the arrangement direction of the first and second cell block assemblies
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes first and second cell block assemblies that include a battery cell stack and are arranged along a direction perpendicular to the stacking direction of the battery cell stack; a module frame that houses the first and second cell block assemblies and is opened in a front and rear direction; and a cooling plate arranged below the bottom portion of the module frame, wherein a flow path through which refrigerant flows is formed in the cooling plate, and the flow path is formed in a direction parallel to the arrangement direction of the first and second cell block assemblies.