Battery Module Cooling Structure Minimizing Conduit Bending

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Solution Overview

Problem

Conventional battery modules face increased manufacturing costs and reduced cooling efficiency due to bent coolant conduits, which also lead to higher product defect rates due to complex coupling of cooling manifolds.

Innovation Solution

A battery module design with a frame member having integrated cooling manifold elements at opposite ends, forming a U-shaped coolant channel, reduces coolant conduit bending, maintains coolant pressure, and allows visual inspection of coupling regions, thereby lowering costs and defect rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If coolant conduit is bent to connect cooling manifolds in conventional battery modules, then the cooling system can be implemented, but manufacturing cost increases and cooling efficiency decreases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling manifolds are integrated with the frame member as a single unified structure, eliminating the need for separate cooling manifold components and their associated bent coolant conduits. This merging reduces manufacturing complexity and cost while improving cooling efficiency through direct thermal coupling between the frame member and battery cells.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The frame member serves multiple functions: it provides structural support for the battery cells and simultaneously acts as a cooling manifold with integrated coolant channels. This multi-functionality eliminates the need for separate cooling components, reducing manufacturing cost and improving reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If cooling manifolds are coupled complexly in conventional battery modules, then the cooling system can be assembled, but product defect rate increases

Engineering Contradiction:

Improveproduct defect rateVSAvoidcoupling process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling manifolds are merged into the frame member structure, eliminating complex coupling operations between separate components. The integrated design removes multiple assembly steps and potential failure points, thereby reducing product defect rates.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The frame member with integrated cooling manifolds serves itself by incorporating the cooling function directly into the structural component, eliminating the need for separate cooling manifold assembly and reducing coupling complexity.

Inventive Principle:

Principle #25Self-service

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 minimizes manufacturing costs, enhances cooling efficiency, and reduces product defects by simplifying the coupling process and maintaining coolant pressure within the battery module.

Implementation Method 1

a coolant conduit having a hollow structure located at an outer edge of the cooling fin

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

the cooling member including a plate-shaped cooling fin having a shape and a size corresponding to those of the battery cells and a coolant conduit having a hollow structure located at an outer edge of the cooling fin

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10333185B2Battery module including cooling structure in which coolant channel is minimally bent

Publication Date: 2019.06.25 LG ENERGY SOLUTION LTD

AI summary

Disclosed herein is a battery module configured to have a structure in which two or more unit modules, each of which includes one or more battery cells, a frame member configured to have a structure to surround outer edges of the one or more battery cells, the frame member including cooling manifold elements located at opposite ends of one side of the outer edges of the battery cells, and a cooling member mounted in the frame member such that the cooling member faces the battery cells while being in contact with the battery cells, the cooling member including a plate-shaped cooling fin having a shape and a size corresponding to those of the battery cells and a coolant conduit having a hollow structure located at an outer edge of the cooling fin, are arranged while being in tight contact with each other, wherein the coolant conduit includes a coolant inlet port and a coolant outlet port connected to the cooling manifold elements of the frame member of each of the unit modules in a communicating fashion.