Battery Module Cell Holder Assembly Thermal Management

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Solution Overview

Problem

Lithium ion battery cells in energy storage devices experience inefficient heat dissipation, leading to performance degradation and potential thermal runaway, especially in compact applications like electric vehicles, where existing cooling methods are either ineffective or bulky.

Innovation Solution

A battery module design featuring a casing with a cell holder assembly that uses a liquid coolant to flow through openings in the cell holders, ensuring direct contact and efficient heat extraction from the cells, with packaging members sealing the coolant and preventing leakage, allowing for effective heat dissipation without adding bulk.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If air-filled gap is used between battery cells and casing, then manufacturing simplicity is improved, but heat dissipation efficiency deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent introduces a thermal interface material as an intermediary substance between the battery cells and the heat dissipation member. This material fills the gaps and improves thermal contact without requiring complex manufacturing processes, thus resolving the contradiction between manufacturing simplicity and heat dissipation efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the thermal conductivity parameter of the interface between battery cells and heat dissipation member by introducing a thermally conductive material. This parameter change enables effective heat transfer while maintaining the simple air-gap structure, resolving the contradiction without complex manufacturing

Inventive Principle:

Principle #35Parameter changes

2Temperature

If liquid coolant flow path is introduced through cell holders, then heat dissipation efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cell holder structure serves multiple functions: it provides mechanical support for battery cells and simultaneously acts as a coolant flow channel. This multi-functionality integrates the cooling system into the existing structure, improving heat dissipation without significantly increasing device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the cell holder structure with the coolant flow path, combining mechanical support and thermal management functions into a single integrated component. This reduces the number of separate parts and simplifies the overall cooling system complexity

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If packaging members are added to seal coolant, then reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecoolant sealing reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses flexible packaging members (gaskets) to seal the coolant flow paths. These thin film elements provide reliable sealing while being easy to install and replace, thus improving reliability without significantly increasing manufacturing or assembly complexity

Inventive Principle:

Principle #30Flexible shells and thin films

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 design provides efficient and safe heat management, maintaining battery longevity and performance while being lightweight and easy to assemble, with the coolant flow ensuring thermal stability and mechanical stability of the battery module.

Implementation Method 1

The coolant flows from the inlet manifold in the cell holder assembly through the openings in the cell holders sequentially located in the cell holder assembly. It extracts heat from the cells in the cell holders

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20230170551A1Battery module with a cell holder assembly

Publication Date: 2023.06.01 TVS MOTOR CO LTD

AI summary

A battery module for a powered device includes: a casing that includes a top cover and a bottom cover; cells disposed between the top cover and the bottom cover; and a cell holder assembly comprising cell holders that accommodate the cells. The cell holder assembly includes an inlet manifold and an outlet manifold that enable a coolant to flow through the cell holders sequentially from the inlet manifold to the outlet manifold to extract heat generated by each of the cells.