Battery Module Case Integrating Cooling Channels and Resin Layer

Solution Overview

Problem

The construction of battery modules for medium and large devices like automobiles and energy storage systems is hindered by the need for various fastening parts and cooling equipment, which increases manufacturing costs, volume, and weight, while reducing power density.

Innovation Solution

A battery module design featuring a thermally conductive module case with an integrated resin layer that allows for efficient heat dissipation and reduced fastening requirements, enabling more cells per unit volume with improved power-to-weight ratio.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If various fastening parts and cooling equipments are used to construct battery modules for medium and large devices, then the structural stability and cooling performance are improved, but the manufacturing cost, volume, and weight increase, and power density decreases

Engineering Contradiction:

Improvestructural stabilityVSAvoidmodule weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The module case integrates both structural support and cooling functions into a single component. The case includes cooling channels formed within its structure, eliminating the need for separate cooling equipment. This merging of functions reduces the number of parts, decreases weight, and simplifies the overall module construction while maintaining both structural stability and cooling performance

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If various fastening parts and cooling equipments are used to construct battery modules for medium and large devices, then the structural stability and cooling performance are improved, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The module case integrates both structural support and cooling functions into a single component. The case includes cooling channels formed within its structure, eliminating the need for separate cooling equipment. This merging of functions reduces the number of parts, decreases weight, and simplifies the overall module construction while maintaining both structural stability and cooling performance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The module case serves multiple functions simultaneously: it provides structural support for the battery cells, acts as a thermal management system through integrated cooling channels, and serves as a protective enclosure. This multi-functionality reduces the total component count and manufacturing complexity, leading to lower production costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If various fastening parts and cooling equipments are used to construct battery modules for medium and large devices, then the structural stability and cooling performance are improved, but the volume increases and power density decreases

Engineering Contradiction:

Improvestructural stabilityVSAvoidmodule volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The module case integrates both structural support and cooling functions into a single component. The case includes cooling channels formed within its structure, eliminating the need for separate cooling equipment. This merging of functions reduces the number of parts, decreases weight, and simplifies the overall module construction while maintaining both structural stability and cooling performance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling channels are nested within the walls of the module case structure itself. This nesting approach allows the cooling system to occupy space that would otherwise be structural material, achieving thermal management without increasing the external dimensions of the battery module

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution results in a battery module that is smaller, lighter, and has enhanced heat dissipation characteristics, reducing the need for extensive fastening and cooling equipment, thus achieving higher power density and lower manufacturing costs.

Implementation Method 1

a resin layer in contact with both the battery cell and the module case

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11342627B2Method of manufacturing a battery module

Publication Date: 2022.05.24 LG ENERGY SOLUTION LTD

AI summary

The present application can provide a battery module, a manufacturing method thereof, and a resin composition applied to the manufacturing method. The present application can provide a battery module having excellent power relative to volume, while being manufactured in a simple process and at a low cost, a manufacturing method thereof, and a resin composition applied to the manufacturing method.