Battery Module Cooling Member With Direct-Mount Coolant Channel
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Solution Overview
Problem
Conventional battery modules suffer from reduced heat conduction efficiency due to the use of cooling plates that lengthen the heat transfer path and are prone to thermal deformation during welding, leading to decreased manufacturing efficiency.
Innovation Solution
A battery module design featuring a cooling member with an upper frame and a lower frame, where secondary batteries are directly mounted to the upper frame, and a coolant channel is integrated into the lower frame, eliminating the need for additional heat conductive members and allowing direct contact between batteries and the cooling member, while using adhesives or mechanical joining to enhance bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cooling plate is interposed between the module case and heatsink, then heat conduction efficiency is improved, but the heat transfer path is lengthened and manufacturing complexity increases
Solution Approach 1:
The cooling member integrates the upper frame (previously a separate cooling plate) and lower frame (heatsink) into a single unified structure. The secondary batteries are directly mounted on the upper frame, eliminating the need for a separate cooling plate, while the coolant channel in the lower frame provides heat dissipation functionality. This merging reduces component count and simplifies the heat transfer path.
2Strength
If a cooling plate is welded to the module case and heatsink, then structural strength is improved, but thermal deformation occurs and manufacturing time increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with adhesive bonding (chemical system) for joining the cooling member to the module case and heatsink. This substitution eliminates thermal deformation caused by welding while maintaining bonding strength, and significantly reduces manufacturing time as adhesive bonding is faster and requires less post-processing.
3Stability of the object's composition
If multiple members are welded together, then structural integrity is improved, but manufacturing process efficiency is reduced
Solution Approach 1:
The patent replaces multiple welding operations with a single adhesive bonding process. The cooling member is bonded to both the module case and heatsink using adhesive, eliminating the need for separate welding steps for each joint. This maintains structural integrity through strong adhesive bonding while dramatically improving manufacturing efficiency by reducing process steps and cycle time.
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 improves cooling efficiency by direct contact and reduces manufacturing time and costs by minimizing the number of parts and preventing coolant leakage, enhancing bonding strength and rigidity.
Implementation Method 1
a cooling member configured so that a plurality of secondary batteries are mounted thereto... a coolant channel configured so that a coolant flows therethrough
Implementation Method 2
a coolant channel configured so that a coolant flows therethrough
Data Source
AI summary
Disclosed is a battery module with improved manufacturing efficiency and improved cooling efficiency. The battery module includes a plurality of secondary batteries; and a cooling member configured so that the plurality of secondary batteries are mounted thereto, and the cooling member includes an upper frame having a plate shape with a predetermined length so that the plurality of secondary batteries are mounted to a first surface thereof; and a lower frame coupled to a second surface of the upper frame on a side opposite the first surface and having a coolant channel configured so that a coolant flows through the coolant channel.