Integrated Battery Module Housing With Cooling Channels
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Solution Overview
Problem
Existing battery module designs require multiple components and a module frame to achieve high power, leading to increased manufacturing complexity, weight, and cost, and are inefficient in cooling and assembly.
Innovation Solution
A battery module design featuring multiple cell stacks integrated into a single module housing with insulation, a cooling channel for coolant flow, and a coupling mechanism for adjacent modules, eliminating the need for a separate module frame and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple cell stacks are integrated into a single module housing without a separate module frame, then device complexity and weight are reduced, but structural strength and stability may be compromised
Solution Approach 1:
The module housing and module frame are merged into a single integrated structure. The housing includes both the outer housing body and internal frame structure as one piece, eliminating the need for separate assembly of housing and frame components. This reduces device complexity while maintaining structural strength through the integrated design.
Solution Approach 2:
The module housing serves multiple functions simultaneously: it provides the outer enclosure, internal frame structure for support, cooling channel pathways, and mounting structures for cell stacks. This multi-functionality reduces the number of separate components needed while maintaining all necessary structural and functional requirements.
2Temperature
If a cooling channel is integrated into the module housing, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling channels are integrated directly into the module housing structure during the housing manufacturing process. The housing is designed with internal cavities and passages that serve as cooling channels, eliminating the need for separate cooling plate assembly or additional manufacturing steps for channel creation.
Solution Approach 2:
The module housing simultaneously serves as both the structural enclosure and the cooling system. The housing material and structure are designed to incorporate cooling channel pathways, making the housing a multi-functional component that provides both mechanical support and thermal management.
3Ease of operation
If end walls are designed to engage cell stack end surfaces directly, then assembly ease is improved, but cell stack protection may be compromised
Solution Approach 1:
Insulation members are introduced as intermediary components between the end walls and cell stack end surfaces. These insulation members provide a protective interface that prevents direct contact between the hard end walls and the cell stacks, protecting the cells while still allowing the end walls to engage and secure the stacks in place.
Solution Approach 2:
The insulation members are integrated into the module housing structure, providing both protection for the cell stacks and insulation functions simultaneously. The housing design incorporates these protective elements as part of the overall structure, eliminating the need for separate protective components while maintaining assembly simplicity.
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 simplifies manufacturing, reduces weight and cost, and effectively meets high power demands while providing efficient cooling and assembly of multiple cell stacks within a single module.
Implementation Method 1
a cooling channel for a coolant to flow to cool the series of receiving parts and the series of cell stacks
Data Source
AI summary
A battery module includes a module including a series of cell stacks, each having a series of unit cells arranged in a first direction, and an insulation member insulating at least one unit cell. The battery module also includes a module housing and a series of receiving parts in the module housing accommodating the cell stacks. Each receiving part includes a fixed wall around a respective cell stack and having a portion in contact with the cell stack. The fixed wall includes a pair of end walls at opposite ends of the receiving part in the first direction. The pair of end walls are configured to engage respective end surfaces of the corresponding cell stack in the first direction. The battery module also includes a cooling channel below a floor surface of the module housing for a coolant to flow to cool the receiving parts and the cells stacks.