Battery Module Cooling Plate and Circuit Mounting
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Solution Overview
Problem
Existing battery modules face challenges in efficiently dissipating heat and securely mounting the circuit module, which can lead to moisture infiltration and damage, especially when using multiple batteries in high-power applications like electric vehicles.
Innovation Solution
The battery module incorporates a three-tier cooling system with dissimilar metal materials for effective heat dissipation and a welding-based coupling mechanism for the circuit module, preventing moisture ingress by eliminating the need for holes in the cover and enhancing sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mounting method with holes is used for the circuit module, then the circuit module can be mounted, but moisture infiltration and damage occur
Solution Approach 1:
A coupling portion is introduced as an intermediary component between the cover and the circuit module. This coupling portion includes a body that fits into a recess in the cover and an extending portion that connects to the circuit module, eliminating the need for holes through the cover while maintaining secure mounting and sealing performance
Solution Approach 2:
The mounting structure is segmented into multiple components: the cover with a recess, the coupling portion with body and extending portion, and the circuit module. This segmentation allows the coupling portion to bridge the gap without requiring penetrating holes, thus preventing moisture infiltration while maintaining structural integrity
2Power
If multiple batteries are used in high-power applications, then electric power output increases, but heat dissipation becomes inefficient
Solution Approach 1:
Different regions of the battery module are assigned different thermal management functions. The cover serves as a thermal interface with direct contact to battery packs in specific areas, while the coupling portion acts as a thermal bridge to the circuit module, creating localized heat dissipation pathways that maintain efficiency in high-power applications
3Reliability
If the coupling portion is directly inserted without a coupling hole, then sealing performance improves, but secure mounting becomes difficult
Solution Approach 1:
The cover is pre-formed with a recess that precisely fits the body of the coupling portion. This preliminary structural preparation allows the coupling portion to be securely mounted through friction fit and mechanical interlocking without requiring additional holes or fasteners, thereby maintaining both sealing performance and mounting security
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 ensures efficient heat dissipation and secure mounting of the circuit module, reducing the risk of moisture damage and improving sealing performance, thereby enhancing the reliability and longevity of the battery module.
Implementation Method 1
a first cooling plate (110a), a battery pack (120) mounted on the first cooling plate (110a)
Implementation Method 2
The coupling portion may be fixed to the cover by a weld
Data Source
AI summary
Provided is a battery module including a first cooling plate, a battery pack mounted on the first cooling plate, a cover to shield the battery pack, the cover being coupled to the first cooling plate, a coupling portion fixed to the cover, and a circuit module into which the coupling portion is inserted, the circuit module being mounted on the cover to be electrically connected to the battery pack.