Battery Module Liquid Cooling Layout for Protected Sensing
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Solution Overview
Problem
Existing battery modules using indirect water cooling methods suffer from limited cooling performance and increased volume, leading to reduced energy density, and there is a risk of damage to sensing components due to direct contact with cooling liquids.
Innovation Solution
A battery module design where an insulating cooling liquid directly contacts battery cells and electrical components, with a flow path spacer and bus bar frame assembly facilitating smooth liquid flow and protecting sensing lines and temperature sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect water cooling is used through module housing, then cooling performance is limited, but device complexity is reduced
Solution Approach 1:
The patent merges the cooling liquid flow path directly into the module housing, eliminating the need for separate external cooling devices. The cooling liquid flows through channels formed within the housing structure itself, combining the housing and cooling system into a single integrated component, thereby improving cooling performance without proportionally increasing device complexity.
Solution Approach 2:
The patent introduces a cooling liquid as an intermediary substance that directly contacts the battery cell through the module housing. This cooling liquid acts as a mediator to transfer heat from the battery cell to the external cooling system, enabling more efficient heat dissipation compared to indirect cooling methods.
2Temperature
If separate heatsink is provided outside module housing, then cooling flow path is formed, but overall volume increases
Solution Approach 1:
The patent integrates the cooling flow path channels directly into the module housing structure, merging the housing and cooling system functions. This eliminates the need for separate external heatsinks and cooling devices, thereby improving cooling efficiency while avoiding significant increases in overall battery module volume.
Solution Approach 2:
The cooling flow path channels are nested within the module housing structure itself, utilizing the existing housing space for dual purposes: structural containment and thermal management. This nesting approach allows the cooling system to be embedded within the housing without adding significant external volume.
3Temperature
If cooling liquid directly contacts battery cell, then cooling performance improves, but sensing components may be damaged
Solution Approach 1:
The patent uses the module housing as an intermediary barrier between the cooling liquid and the battery cell. The housing contains the cooling liquid within dedicated flow path channels, allowing thermal contact with the battery cell while preventing direct contact that could damage sensing components. This mediator approach enables direct cooling while protecting sensitive components.
4Temperature
If insulating cooling liquid is introduced, then direct cooling is achieved, but sensing line may be damaged by liquid
Solution Approach 1:
The module housing acts as an intermediary barrier that contains the insulating cooling liquid within controlled flow path channels. This mediator structure allows the cooling liquid to efficiently cool the battery cell while preventing direct contact with the sensing line, thereby maintaining sensing line integrity despite the introduction of direct liquid cooling.
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
Enhances cooling efficiency, maintains accurate temperature measurement, and prevents damage to sensing components while improving energy density.
Implementation Method 1
an insulating cooling liquid flowing into a module housing to cool a battery cell directly contact parts such as an electrode lead, a bus bar, etc. of the battery cell to cause efficient cooling
Data Source
AI summary
A battery module includes a sub module including a cell stack assembly having a plurality of battery cells; a module housing configured to accommodate the sub module; a front sealing plate configured to cover an opening at one longitudinal side of the module housing and having an inlet for introducing an insulating cooling liquid; a rear sealing plate configured to cover an opening at the other longitudinal side of the module housing and having an outlet for discharging the insulating cooling liquid; and a sensing assembly configured to sense voltage of the battery cell.