Battery Module Upper-Side Adhesive Cooling Around Sensing Wires
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules face limitations in cooling performance due to restricted application of thermally conductive adhesive, primarily on the lower side, which hinders uniform cooling and design flexibility, especially when components like voltage sensing lines are present.
Innovation Solution
A battery module design that includes a sensing assembly covering the battery cell assembly, with a thermally conductive adhesive applied between the module case's upper inner surface and the battery cell assembly, allowing for cooling through the upper side, facilitated by a tubular rectangular monoframe module case and injection holes for efficient adhesive distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermally conductive adhesive is applied only on the lower side of the battery cell assembly, then the structure is simple and easy to manufacture, but the cooling performance is insufficient and non-uniform
Solution Approach 1:
The cooling system is segmented into two independent cooling paths: upper side cooling through thermally conductive adhesive applied to the upper surface of the battery cell assembly, and lower side cooling through adhesive applied to the lower surface. This segmentation allows each cooling path to operate independently, improving overall cooling performance and uniformity while maintaining manufacturing simplicity.
Solution Approach 2:
The cooling approach transitions from a single-dimensional (lower side only) cooling system to a two-dimensional cooling system by adding upper side cooling capability. This dimensional expansion enables heat to be dissipated from both the top and bottom surfaces of the battery cell assembly, significantly improving cooling uniformity and effectiveness.
2Measurement precision
If voltage sensing lines are disposed on the battery cell assembly, then the battery module can sense voltage, but the application of thermally conductive adhesive is restricted and uniform cooling becomes difficult
Solution Approach 1:
The thermally conductive adhesive is applied selectively in specific regions of the upper surface that do not interfere with the voltage sensing lines. This local quality approach allows the adhesive to be placed only where thermal conduction is needed, avoiding the sensing line areas, thereby maintaining both voltage sensing capability and improved thermal management in the permissible zones.
3Device complexity
If cooling is performed only through the lower side of the battery cell assembly, then the structure is simple, but design flexibility is limited and cooling performance cannot be improved when lower side cooling is insufficient
Solution Approach 1:
The battery module cooling system is designed with multi-functionality by enabling both upper and lower side cooling capabilities. This universal cooling approach allows the system to adapt to different thermal management requirements and design scenarios, providing flexibility to optimize cooling performance based on specific application needs while maintaining a relatively simple overall structure.
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 design enables uniform cooling on both the upper and lower sides of the battery cell assembly, improving cooling performance, reducing production costs and weight, and enhancing the module's tolerance to vibrations and impacts.
Implementation Method 1
a thermally conductive adhesive interposed between an upper inner surface of a module case and an upper side of the battery cell assembly
Data Source
AI summary
A battery module includes a battery cell assembly having a plurality of battery cells, a sensing assembly which covers a front and rear of the battery cell assembly when mounted thereto, a module case which receives the battery cell assembly and the mounted sensing assembly, and a thermally conductive adhesive interposed between an upper inner surface of the module case and an upper side of the battery cell assembly. The sensing assembly includes a first busbar frame assembly positioned at the front of the battery cell assembly, a second busbar frame assembly positioned at the rear of the battery cell assembly, and a sensing wire which connects the first and second busbar frame assemblies and runs across the upper side of the battery cell assembly in a diagonal direction. The thermally conductive adhesive is disposed on two sides of the sensing wire.