Battery Module Heat Sink Layout for Shorter Cooling Paths
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Solution Overview
Problem
Conventional battery modules face challenges in effectively dissipating heat due to complex heat transfer paths and reduced heat conducting characteristics, which can lead to accelerated deterioration and increased risk of explosion or ignition, particularly in large-sized modules exposed to high temperatures.
Innovation Solution
A battery module design featuring a first heat sink with an integrated cooling flow passage and a simplified heat transfer path, where a first heat sink with a partition wall is located above the module frame, allowing direct coolant contact with the module frame, and supplemented by a second heat sink and thermally conductive resin layer, enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of battery cells are stacked to increase capacity, then the battery module can provide higher power and energy, but the heat generated from the battery cells accumulates more quickly and severely, making heat dissipation difficult
Solution Approach 1:
The patent transitions from conventional single-side cooling to dual-side cooling by placing heat sinks at both the upper and lower parts of the module frame. This dimensional expansion allows heat to be dissipated from multiple directions simultaneously, effectively managing heat accumulation from the increased number of battery cells.
Solution Approach 2:
The cooling system is segmented into multiple independent heat sinks (first heat sink at the upper part, second heat sink at the lower part) that can independently dissipate heat from different regions of the battery cell stack, improving overall heat dissipation efficiency.
2Device complexity
If conventional heat transfer paths are used with multiple layers (thermally conductive resin layer, module frame, heat transfer member, heat sink), then the structure is established, but the heat transfer path becomes complex and heat conducting characteristics are reduced
Solution Approach 1:
The module frame and heat transfer member are merged into a single integrated component. This eliminates the air gaps and thermal resistance interfaces between separate layers, creating a direct heat transfer path from the battery cells to the heat sinks while simplifying the overall structure.
Solution Approach 2:
The thermally conductive resin layer is removed from the heat transfer path. By directly coupling the battery cells to the integrated module frame/heat transfer member, the patent eliminates the additional thermal resistance introduced by the resin layer while maintaining effective thermal contact.
3Strength
If the module frame is made thicker or more robust to house the battery cell stack, then the structural strength is improved, but the heat conducting characteristics are reduced due to the increased distance for heat transfer
Solution Approach 1:
The module frame and heat transfer member are combined into a single component that simultaneously provides both structural support and efficient heat conduction. This integration ensures that the frame maintains its strength while the heat transfer path remains as short and direct as possible.
Solution Approach 2:
The integrated module frame/heat transfer member is made from aluminum or aluminum alloy, which provides both the required mechanical strength and excellent thermal conductivity. This composite approach allows the single component to fulfill both structural and thermal management functions effectively.
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 improves cooling efficiency by simplifying the heat transfer path, reducing temperature deviations, and minimizing the risk of explosion or ignition, while maintaining a compact size and reducing costs.
Implementation Method 1
heat generated from the battery cells passes through a thermally conductive resin layer, a bottom part of a module frame, a heat transfer member, and a heat sink in this order along the direction D, and then is transferred to the outside of the battery module
Implementation Method 2
a first cooling flow passage through which a coolant flows to make contact with the upper cover of the module frame
Data Source
AI summary
The battery module according to one embodiment of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked; a module frame housing the battery cell stack; and a first heat sink located at an upper part of the module frame, wherein the first heat sink includes an upper plate and a lower plate, wherein a lower plate of the first heat sink constitutes an upper cover of the module frame, and wherein the first heat sink includes a cooling flow passage having at least one partition wall is-formed between the upper plate and the upper cover of the module frame.