Integrated Battery Module Cooling Housing for Compact Cell Assembly
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Solution Overview
Problem
Conventional battery modules require separate fixing and cooling components, leading to increased volume, complexity, and manufacturing costs, with inefficiencies in cooling and assembly due to separate components and tolerances in cell stacking.
Innovation Solution
A battery module design featuring a single-piece cooling housing with protrusions and recesses for improved contact and assembly, along with a heat transfer member for enhanced cooling efficiency, and a manufacturing method that minimizes the use of fixing/heat transfer resin and simplifies the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate fixing members and cooling members are used for battery cells, then the battery module can be assembled with conventional components, but the volume of the battery module increases and space utilization decreases
Solution Approach 1:
The patent integrates the cooling member and fixing member into a single integrated component that simultaneously performs both cooling and structural support functions. The cooling housing includes cooling plates positioned to contact battery cells while also serving as structural elements that fix the cells in place, eliminating the need for separate fixing members and reducing overall module volume.
Solution Approach 2:
The cooling housing is designed as a multi-functional component that provides both thermal management and mechanical support. The cooling plates not only transfer heat from battery cells but also serve as structural supports that maintain cell positioning and provide rigidity to the overall module structure.
2Temperature
If separate cooling members such as cooling fins and cooling plates are used, then cooling function is provided, but the volume increases and energy density decreases
Solution Approach 1:
The cooling function is integrated directly into the housing structure through cooling plates that are part of the cooling housing assembly. This eliminates the need for separate cooling fins and dedicated cooling components, reducing the overall volume occupied by cooling systems and increasing the proportion of active battery material in the module.
3Ease of manufacture
If respective sides of the battery module case are separately prepared and coupled, then the case can be manufactured with standard processes, but the manufacturing process becomes complicated and time increases
Solution Approach 1:
The cooling housing is designed as an integrated assembly where cooling plates and structural supports are combined into a single manufactured component or pre-assembled unit. This reduces the number of separate case sides that need to be prepared and coupled, simplifying the overall assembly process and reducing manufacturing time despite using standard manufacturing processes for the housing itself.
4Temperature
If cooling members are mounted on battery cells with electric insulation thermal conductive members, then cooling efficiency is improved, but the device complexity increases
Solution Approach 1:
The cooling plates are designed to directly contact battery cells without requiring separate electric insulation thermal conductive members. The cooling housing structure itself provides the necessary thermal conduction path while maintaining electrical insulation through its design, eliminating the need for additional intermediate components and reducing overall device complexity.
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 design maximizes space utilization and energy density, enhances cooling efficiency, and reduces manufacturing time and costs by integrating cooling components and simplifying the assembly process, while preventing issues like non-contacting cells and laser beam penetration during assembly.
Implementation Method 1
a heat transfer member for enhanced cooling efficiency
Data Source
AI summary
The present invention provides a battery module, which includes: a battery group formed by stacking a plurality of battery cells, each of which includes electrode tabs; a cooling housing including a cooling plate located corresponding to one side of sides of the battery group, in which the electrode tabs are not extended, and side plates located on both sides of the battery group perpendicular to the one side of the sides, thus to house the battery group; a cover plate located on the other side of the battery group; and a front cover part and a rear cover part, which are located at outermost front and rear of the battery group on both sides in a direction in which the electrode tabs are extended.