Integrated Battery Module Cooling Assembly With Fewer Components
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Solution Overview
Problem
Conventional battery modules suffer from increased volume, weight, and cost due to unnecessary components, which also decrease productivity and design freedom.
Innovation Solution
A battery module design featuring a center cartridge assembly with integrated cooling plates, side cooling covers, and a busbar housing assembly that minimizes unnecessary elements while enhancing insulation and cooling performance, allowing for reduced component count and improved design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery modules include protrusions for temperature sensors, through holes filled with glue, radiation holes, and support holes for heat sinks, then temperature monitoring and cooling functions are achieved, but volume, weight, and component complexity increase
Solution Approach 1:
The patent merges the cooling plate and support structure into a single integrated component. The cooling plate directly contacts the battery cells at multiple points, eliminating the need for separate support holes, protrusions, and heat sink assemblies. This integration reduces component count while maintaining thermal management functionality.
Solution Approach 2:
The cooling plate serves multiple functions simultaneously: it provides structural support for the battery cells, conducts heat away from the cells, and eliminates the need for separate temperature sensor mounting structures. This multi-functionality reduces overall device complexity while achieving the same reliability goals.
2Reliability
If conventional battery modules include multiple support holes and mounting structures for heat sinks and temperature sensors, then proper positioning and thermal management are achieved, but weight and volume increase
Solution Approach 1:
The cooling plate integrates structural support and thermal management functions into a single component, eliminating the need for separate support structures, mounting brackets, and heat sink assemblies. This reduction in component count directly reduces the overall weight of the battery module.
3Temperature
If conventional battery modules include radiation holes and extension direction holes in columns, then cooling efficiency is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The cooling plate features multiple discrete contact points with the battery cells, segmenting the thermal management function across multiple locations. This segmentation provides effective cooling without requiring complex hole patterns or radiation holes, simplifying the manufacturing process while maintaining cooling efficiency.
4Stability of the object's composition
If conventional battery modules use fixed structures with through holes and glue filling, then assembly stability is achieved, but design freedom and adaptability decrease
Solution Approach 1:
The cooling plate design allows for flexible adaptation to different battery cell arrangements and configurations. The integrated structure can be customized for various cell types, voltages, and current combinations without requiring fixed through-holes or glue-filled assemblies, providing both stability and design freedom.
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 new design reduces volume, weight, and cost while improving cooling efficiency and design freedom, simplifying assembly, and enabling various serial-parallel combinations of battery cells.
Implementation Method 1
a cooling plate inner installed in the center cartridge assembly and configured to cool parts of the battery cells
Implementation Method 2
a cooling plate outer attached to the side cooling cover assembly and configured to cool parts of the battery cells
Data Source
AI summary
The present disclosure provides a battery module including a center cartridge assembly, on which a plurality of battery cells are arrayed and seated, including a cooling plate inner installed therein and configured to cool a part of each of the battery cells, a side cooling cover assembly which is coupled to two sides of the center cartridge assembly to protect the battery cells seated on the center cartridge assembly and includes a cooling plate outer attached thereto and configured to cool a part of each of the battery cells, and a busbar housing assembly which is coupled to an upper portion of the center cartridge assembly and includes one or more output busbars installed thereon and configured to be electrically connected to an electrode exposed at an upper portion of each of the battery cells.