Battery Module Cooling Plate Design for Volume Reduction
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Solution Overview
Problem
The efficiency and performance of battery modules are compromised by high temperatures, leading to reduced battery life, and existing cooling systems often increase the overall volume of the module.
Innovation Solution
A battery module design featuring a case with a main frame and side covers formed from resin materials, laser-welded together, incorporating a cooling unit with a cooling plate and heat dissipating member to efficiently dissipate heat externally, while reducing the module's volume through a thin cooling plate and indirect cooling method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cooling unit is added to dissipate heat from battery cells, then temperature control and battery life are improved, but the volume of the battery module increases
Solution Approach 1:
The cooling plate is integrated between the battery cells themselves, merging the cooling function with the structural arrangement of the battery cells. This eliminates the need for separate cooling chambers or external cooling systems, thus dissipating heat effectively while minimizing volume increase.
Solution Approach 2:
The cooling plate utilizes the interstitial space between battery cells in the vertical/dimensional direction rather than expanding the horizontal volume. By placing cooling plates between cells in a stacked arrangement, the system achieves effective heat dissipation without significantly increasing the overall module footprint.
2Volume of stationary object
If a thin cooling plate is used to reduce volume, then battery module volume is reduced, but cooling efficiency may be compromised
Solution Approach 1:
Multiple thin cooling plates are distributed between individual battery cells or groups of cells, segmenting the cooling function across multiple contact points. This ensures that each cell or cell group has direct thermal contact with a cooling surface, maintaining high cooling efficiency despite the thin profile of each individual plate.
Solution Approach 2:
The cooling plates are positioned at specific locations where heat generation is most intense, such as between cells with higher current density or thermal output. The local placement optimizes heat dissipation at critical hot spots while using thin plates to minimize overall volume impact.
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 effectively reduces the battery module's volume and enhances cooling efficiency, preventing temperature-related performance degradation and maintaining the module's integrity by sealing the internal space and managing cell expansion.
Implementation Method 1
at least one cooling unit interposed between the battery cells to be in surface contact with the battery cells and dissipating heat generated by the battery cells externally
Implementation Method 2
All of the main frame and the side covers may be formed of a resin material, and may be bonded to each other by laser welding
Data Source
AI summary
A battery module and a method of manufacturing the same are provided. The battery module includes a case providing an internal space, a plurality of battery cells disposed in the internal space of the case, and at least one cooling unit interposed between the battery cells to be in surface contact with the battery cells and dissipating heat generated by the battery cells externally.