Battery Module Cooling via Integrated Housing Cold Plate
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Solution Overview
Problem
Battery modules in electric vehicles face premature aging due to heat generated from Joule heating, chemical reactions, and ambient temperatures, leading to increased localized temperatures that can cause physical distortion and reduce battery life.
Innovation Solution
A cooling system featuring a cold plate with a fluid circuit and parallel cross-flow tubes that convey coolant along the external surface of the battery module housing, enhanced by air flow and adjustable design to fit various module configurations, effectively dissipates heat without significantly increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is added to the battery module, then heat dissipation is improved, but weight increases
Solution Approach 1:
The cooling system is integrated with the battery module housing structure, merging the cooling function into the existing structural components rather than adding separate cooling components, thereby reducing weight while maintaining effective heat dissipation
Solution Approach 2:
The housing structure serves dual purposes: structural support and heat dissipation. The housing is designed to act as both a protective enclosure and a thermal management system, eliminating the need for dedicated heavy cooling components
2Temperature
If a large cooling surface is used to contact the housing, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The cooling surface is merged with the housing structure itself, using the housing walls as the cooling surface. This integration simplifies the overall system by eliminating separate cooling components while providing adequate heat dissipation area
Solution Approach 2:
The housing performs multiple functions simultaneously: structural support, protection, and heat dissipation. The same structural components that provide mechanical support also serve as the cooling surface, reducing system complexity
3Volume of stationary object
If tight packaging of multiple cells is used, then space utilization is improved, but temperature increase is aggravated
Solution Approach 1:
The housing structure is designed with differentiated thermal properties in different regions. Areas with higher heat generation have enhanced cooling capabilities through the integrated housing design, while maintaining tight packaging in cooler regions
Solution Approach 2:
Heat dissipation is addressed by utilizing the external surface of the housing in three-dimensional space. The cooling system uses the outer housing surfaces to dissipate heat to the surrounding environment, adding a spatial dimension for thermal management without increasing internal cell spacing
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 cooling system prevents premature aging of battery cells by maintaining optimal temperatures, enabling higher current handling and potentially repurposing waste heat for vehicle comfort, while being adaptable to different battery module designs.
Implementation Method 1
a first cooling surface of the cooling system is in contact with an external surface of the housing of the battery module to receive the excess heat
Implementation Method 2
a cold plate with a fluid circuit that routes a coolant through the cold plate
Data Source
Figure 1~2
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Figure 4
AI summary
Systems are disclosed for battery modules 12 with cooling systems 30. In accordance with disclosed embodiments, the cooling system 30 may be disposed against an external surface of a housing 34 of the battery module 12. The cooling system 30 may utilize a coolant to remove heat generated by cells 32 within the battery module 12, to prevent the cells 32 from aging prematurely. Embodiments of the cooling system 30 may include cold plates, tubes, fins, and plates, or a combination thereof, which may route the coolant along the surface of the battery module housing 34. Such features may create a large effective cooling surface against the battery module housing 34 to promote a high heat transfer rate from the cells 32 to the coolant.