Integrated Battery Housing with Cooling Channels
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Solution Overview
Problem
The manufacturing costs and assembly complexity of high-output and large-capacity battery modules are increased due to the need for multiple electrical connecting members, which can lead to short circuits if incorrectly assembled, and inefficient heat removal results in degradation of unit cells.
Innovation Solution
A housing member with integrally formed electrically connecting members that also defines refrigerant flow channels, reducing manufacturing costs and simplifying assembly by integrating electrical connections and cooling functions into a single component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate electrical connecting members are used to connect unit cells and external devices, then electrical connection functionality is achieved, but manufacturing costs increase and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate electrical connecting members into a single integrated housing member that includes all necessary electrical connection components (positive terminal connector, negative terminal connector, and insulation members) as integral parts. This merging eliminates the need for separate assembly steps and reduces the total number of components, directly addressing the contradiction by reducing assembly complexity while maintaining all required electrical connection functionalities.
Solution Approach 2:
The housing member is designed to perform multiple functions simultaneously: it provides structural housing, electrical connection between unit cells, electrical connection to external devices, and insulation between positive and negative terminals. This multi-functionality allows a single component to replace what would traditionally require multiple separate components, thereby reducing manufacturing costs and assembly complexity while achieving all necessary electrical connection objectives.
2Reliability
If multiple separate electrical connecting members are used, then electrical connection is achieved, but the risk of short circuits due to assembly mistakes increases
Solution Approach 1:
By integrating the insulation members and electrical connecting members into a single housing member, the patent eliminates the risk of assembly mistakes that could cause short circuits. The insulation structures are pre-positioned and fixed relative to the electrical connectors, ensuring that positive and negative terminals are always properly isolated. This integrated design removes the variability and human error associated with assembling multiple separate components.
3Productivity
If traditional separate components are used for electrical connection and cooling, then individual functions are achieved, but overall system efficiency decreases
Solution Approach 1:
The patent merges the electrical connection system and cooling system into a single integrated housing member. The refrigerant flow channels are formed as integral parts of the housing structure, eliminating the need for separate cooling components. This integration streamlines the assembly process, improves productivity by reducing the number of assembly steps, and maintains all necessary functions (electrical connection, insulation, and cooling) within a unified component design.
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
This solution reduces manufacturing costs, prevents short circuits, and enhances cooling efficiency by allowing for uniform refrigerant flow and heat removal, thereby improving the overall performance and reliability of battery modules.
Implementation Method 1
a flow channel of refrigerant is defined in the battery module
Data Source
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AI summary
Disclosed herein is a housing member for a battery module, which is mounted to at least one side of the battery module such that a flow channel of refrigerant is defined in the battery module having unit cells stacked therein, wherein the housing member is provided with electrically connecting members for electrically connecting electrode terminals of the unit cells with each other and/or electrically connecting an external device to the electrode terminals, the electrically connecting members being integrally formed at the housing member. The housing member according to the present invention is manufactured in a structure in which the electrically connecting members are integrally formed at the housing member. Consequently, the manufacturing costs of the housing member are reduced. Furthermore, the assembly process of the battery module is greatly simplified, and the occurrence of short circuits caused by an engineer's mistake is effectively prevented.