Battery Module With Integrated Cooling Passage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face cooling inefficiencies due to separate cooling devices, leading to potential cooling losses.
Innovation Solution
A battery module design incorporating a cell assembly with a lower plate featuring a cooling passage between inner and outer plates, bonded using cold metal transfer (CMT) and friction stir welding (FSW), allowing for enhanced cooling performance without the need for a separate cooling device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate cooling device is used to cool the battery module, then the cooling function is provided, but cooling loss occurs and device complexity increases
Solution Approach 1:
The cooling device is merged with the battery module by integrating the cooling passage directly into the lower plate structure. The lower plate now serves dual functions: structural support and heat dissipation. This integration eliminates the need for separate cooling components and reduces cooling loss by creating direct thermal contact between the battery cells and cooling passage.
Solution Approach 2:
The lower plate is designed to perform multiple functions simultaneously: it provides structural support for the battery module while also serving as a heat dissipation component with integrated cooling passages. This multi-functionality reduces the overall number of components and eliminates cooling loss associated with separate cooling devices.
2Temperature
If a separate cooling device is used, then cooling is provided, but device complexity increases
Solution Approach 1:
The cooling device is merged with the battery module by integrating the cooling passage directly into the lower plate structure. The lower plate now serves dual functions: structural support and heat dissipation. This integration eliminates the need for separate cooling components and reduces cooling loss by creating direct thermal contact between the battery cells and cooling passage.
Solution Approach 2:
The lower plate is designed to perform multiple functions simultaneously: it provides structural support for the battery module while also serving as a heat dissipation component with integrated cooling passages. This multi-functionality reduces the overall number of components and eliminates cooling loss associated with separate cooling devices.
3Strength
If multiple joining portions are used to bond the outer plate to the inner plate, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The joining process is segmented into two distinct portions: a first joining portion along the edge of the outer plate and a second joining portion inside the outer plate. Each portion uses a different welding method optimized for its specific requirements, allowing for improved bonding strength while maintaining manufacturing feasibility through specialized process zones.
Solution Approach 2:
Different welding methods are applied to different regions of the plate assembly. The first joining portion uses CMT welding optimized for edge bonding, while the second joining portion uses FSW optimized for internal plate bonding. This local specialization of welding techniques maximizes bonding strength in each region while maintaining overall manufacturing efficiency.
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 increases cooling efficiency by integrating the cooling passage within the module, reducing the risk of cooling losses and providing effective heat dissipation directly within the battery module.
Implementation Method 1
a cooling passage and disposed between the inner plate and the outer plate
Implementation Method 2
The first joining portion may be provided by cold metal transfer (CMT) welding
Implementation Method 3
The second joining portion may be provided by friction stir welding (FSW)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A battery module includes a cell assembly in which a plurality of battery cells are stacked, and a lower plate, having a cooling passage and disposed below the cell assembly. The lower plate includes an inner plate disposed below the cell assembly, an outer plate, disposed outside of the inner plate and bonded to the inner plate, a first joining portion disposed along an edge of the outer plate to bond the outer plate to the inner plate, and a second joining portion disposed inside the outer plate to bond the outer plate to the inner plate.