Corrugated Flexible Plate for Battery Module Fluid Expansion
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Solution Overview
Problem
Existing immersion cooled battery modules face issues with thermal expansion of the tempering fluid leading to pressure increases, which can damage the module, and require complex and costly solutions like balloons or bellows for pressure equalization.
Innovation Solution
A battery module design with a flexible plate covering openings in the housing, allowing the tempering fluid to expand into a space between the housing and the plate, which deforms to accommodate volume changes without significant pressure increases, using a corrugated shape to facilitate easy production and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery modules are tightly packed to increase energy density, then space utilization is improved, but thermal expansion during charging causes deformation and potential damage
Solution Approach 1:
The battery module is segmented into multiple battery packs arranged in a matrix, with through-holes provided in the side walls between adjacent battery packs. This segmentation allows independent expansion compensation for each battery pack while maintaining overall tight packing, resolving the contradiction between space utilization and deformation prevention
Solution Approach 2:
Electrolyte serves as an intermediary substance that flows through the through-holes to provide lubrication and expansion compensation. The electrolyte mediates between the battery packs and module housing, allowing thermal expansion without direct contact and potential damage, thus maintaining both tight packing and reliability
2Reliability
If expansion compensation structures are added to prevent deformation, then reliability is improved, but device complexity increases
Solution Approach 1:
The through-holes serve multiple functions: they provide electrolyte flow paths for expansion compensation, acts as lubrication channels, and maintain structural integrity. This multi-functionality achieves deformation prevention without adding separate dedicated expansion compensation structures, thus improving reliability while minimizing increased complexity
3Ease of operation
If lubrication is applied to reduce friction during expansion, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The module housing is designed with integrated through-holes that maintain alignment through the housing structure itself rather than requiring separate precision components. The housing acts as a flexible container that can accommodate slight variations, reducing the need for high manufacturing precision while still enabling smooth expansion movement with electrolyte lubrication
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 design ensures efficient temperature control and homogeneous cooling of battery cells, allowing operation in any orientation and under mechanical stress without pressure buildup, while being cost-effective and easy to manufacture.
Implementation Method 1
the electrolyte may be provided with lubrication properties to reduce friction between the battery pack and the module housing
Implementation Method 2
the battery pack may expand during charging
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
Provided is a battery module, comprising a housing (10), wherein at least one opening (11) is provided, forming a fluid connection between an inside of the housing and an outside of the housing; a plurality of battery cells (20) arranged in the housing; a tempering fluid included in the housing; a flexible plate (30) arranged on an outside surface of the housing and liquid-tightly covering the at least one opening, wherein the flexible plate is formed of a flexible material allowing for the tempering fluid to expand into a first space (S1) between the outside surface and the flexible plate, and the flexible plate exhibits, in an unstressed state, a corrugated shape.