Battery Module Cold Plate Cut-Outs for Compact Multi-Module Cooling
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Solution Overview
Problem
Existing battery module cooling solutions face inefficiencies due to limited thermal conductivity and increased volume, with external cooling arrangements being suboptimal and integrated cooling complicating manufacturing.
Innovation Solution
A cold plate system with cooling channels and cut-outs to house protruding side plates, allowing for efficient thermal connection with battery cells within the module, reducing material usage and enhancing mechanical stability, while enabling a single large cold plate to cool multiple modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cooling arrangement is placed outside the battery module casing, then the manufacturing process is simpler, but the thermal conductivity is limited and cooling efficiency is reduced
Solution Approach 1:
The cold plate is nested within the battery module casing, with cooling channels positioned between the battery cells and the outer casing. This nested arrangement allows the cooling system to be integrated into the module structure, improving thermal conductivity and cooling efficiency while maintaining relatively simple manufacturing processes through modular assembly
2Temperature
If a cooling arrangement is integrated within the battery casing, then the cooling efficiency is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The battery module is segmented into distinct functional zones: battery cells, cold plate with cooling channels, insulation layer, and outer casing. This segmentation allows each component to be manufactured separately using standard processes, then assembled together, thereby achieving integrated cooling without significantly increasing manufacturing complexity
3Temperature
If a cooling arrangement is added to the battery module, then the cooling capability is enhanced, but the volume of the battery module is increased
Solution Approach 1:
The cooling channels are arranged in the vertical dimension between the battery cells and the outer casing, rather than adding horizontal extensions. This vertical utilization of space allows the cooling system to be integrated within the existing module footprint, enhancing cooling capability without significantly increasing the overall volume of the battery module
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 achieves more efficient cooling, reduces manufacturing complexity and costs, and provides improved mechanical stability and volume efficiency compared to prior solutions.
Implementation Method 1
the base plate is thermally connected to the bottom surface of the battery cells
Implementation Method 2
cooling media via the cooling channels
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5
AI summary
The present invention relates a system 30 comprising a plurality of battery modules (10) and a cold plate (30) for cooling the battery modules. Each battery module comprises a plurality of stacked battery cells (11) and two side plates (12), each side plate having a protruding lower edge (14) supporting a bottom surface (15). The cold plate comprises a base plate (31) provided with cooling channels, wherein the base plate (31) is thermally connected to the bottom surface (15) of the battery cells (11) in each battery module (10); an inlet port (24) for feeding cooling media via the cooling channels to an outlet port (26), and at least one cut-out (32) configured to house one of the protruding lower edges (14) of the side plates (12).