Battery Module Cooling Structure for Lower Cell Temperature Deviation
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Solution Overview
Problem
Existing battery modules face challenges in improving cooling performance and reducing cooling deviation between battery cells, particularly as they become larger and more complex, which can limit output and lifespan.
Innovation Solution
A battery module design featuring a thermal conductive resin layer and heat sink system, with cooling fins and an exterior member made of an elastic material, that directly transfers heat from battery cells to the heat sink, minimizing cooling deviation and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a battery module is designed to accommodate 96 battery cells arranged in a 4x4 matrix, then the battery pack capacity increases, but the height of the battery module becomes excessively large (400mm) making it difficult to assemble into battery packs
Solution Approach 1:
The battery module is divided into an upper module and a lower module, each accommodating a subset of the battery cells. The upper module contains battery cells arranged in a first matrix configuration, while the lower module contains battery cells arranged in a second matrix configuration. This segmentation reduces the height of each individual module while maintaining the total capacity of 96 battery cells when assembled together with the battery pack assembly device.
Solution Approach 2:
The patent introduces a vertical stacking dimension by arranging the upper and lower modules in a stacked configuration. Instead of arranging all 96 battery cells in a single horizontal plane (4x4 matrix), the cells are distributed across multiple vertical layers (upper and lower modules), transforming the spatial arrangement from a two-dimensional matrix to a three-dimensional stacked structure. This dimensional change enables reduced module height while preserving total battery capacity.
2Device complexity
If battery cells are arranged in a fixed 4x4 matrix configuration, then the structural design is simplified, but the ability to adapt to different battery pack requirements is reduced
Solution Approach 1:
The battery module design enables dynamic reconfiguration through the battery pack assembly device, which can selectively combine upper and lower modules in different configurations. The system can adapt between single-module and dual-module arrangements, and can accommodate different numbers and types of battery cells (e.g., cylindrical, prismatic, or lithium sulfur batteries) by adjusting the matrix dimensions and module composition, providing operational flexibility without increasing inherent structural complexity.
Solution Approach 2:
The upper and lower module designs are made universal through standardized interfaces and configurations. Each module can accommodate different battery cell types and arrangements (e.g., 4x4, 4x6, or other matrix configurations) while maintaining the same basic structural framework. This universality allows the same module design to serve multiple battery pack requirements and be assembled in various configurations to meet different capacity and dimensional specifications.
3Manufacturing precision
If the battery module uses a rigid fixed structure, then manufacturing precision is maintained, but the module cannot accommodate thermal expansion or contraction of battery cells
Solution Approach 1:
The support structures incorporate elements with variable physical properties that respond to thermal conditions. The support beams and connection structures are designed to undergo controlled dimensional changes in response to temperature variations, allowing the module to expand or contract thermally while maintaining structural integrity and manufacturing precision under normal operating conditions.
Solution Approach 2:
The module employs flexible connection structures and compliant mounting mechanisms that can accommodate thermal expansion and contraction of battery cells. These flexible elements maintain secure electrical and mechanical connections while allowing for dimensional changes due to temperature variations, thus preserving both manufacturing precision and thermal stability.
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack including a plurality of battery cells stacked in a first direction; a first heat sink located at a lower part of the battery cell stack; a first thermal conductive resin layer located between the battery cell stack and the first heat sink; and an exterior member surrounding the outer surface of the battery cell stack, wherein the battery cell stack comprises at least one cooling fin located between battery cells adjacent to each other among the plurality of battery cells, and wherein the first thermal conductive resin layer and the first heat sink are located between the exterior member and a lower surface of the battery cell stack.