Battery Module Metallic Cooling Profiles
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Solution Overview
Problem
Existing battery modules for electric vehicles face challenges in achieving high packing density and efficient heat dissipation while minimizing space and weight, which affects power density and range.
Innovation Solution
The battery module incorporates metallic hollow cooling profiles with a star-shaped cross-section that fit tightly between cylindrical battery cells, providing extensive contact surfaces for heat dissipation and mechanical separation, utilizing extruded aluminum alloy for lightweight construction and efficient cooling fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling with heat distribution elements is used, then heat dissipation is improved, but space requirement increases
Solution Approach 1:
The patent transitions from air cooling to liquid cooling by introducing cooling channels through which cooling fluid flows. This hydraulic cooling system achieves superior heat dissipation efficiency in a more compact configuration, resolving the contradiction between heat dissipation performance and space requirement
Solution Approach 2:
The patent changes the cooling medium from gas (air) to liquid (cooling fluid), fundamentally altering the heat transfer parameter. Liquid cooling provides higher heat transfer coefficients, enabling effective heat dissipation with reduced space, thus resolving the technical contradiction
2Quantity of substance
If battery cells are packed tightly to increase power density, then space utilization is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent merges the structural support function with the cooling function by integrating cooling channels into the housing structure that directly contacts battery cells. This combination allows tight packing while maintaining effective heat dissipation pathways, resolving the contradiction between packing density and heat dissipation
Solution Approach 2:
The cooling fluid acts as an intermediary medium that extracts heat from tightly packed battery cells through the housing structure. This intermediary cooling system enables high packing density while maintaining effective heat removal, resolving the technical contradiction
3Temperature
If more cooling structure is added to improve heat dissipation, then cooling performance is improved, but device complexity increases
Solution Approach 1:
The housing structure serves multiple functions simultaneously: structural support, mechanical protection, and heat dissipation through integrated cooling channels. This multi-functionality reduces the need for separate cooling components, resolving the contradiction between cooling performance and device complexity
Solution Approach 2:
The patent combines the housing structure with the cooling system by integrating cooling channels directly into the housing. This merger eliminates the need for separate cooling components, achieving effective cooling while minimizing structural 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
This design achieves a high packing density of over 70% of the module's cross-sectional area, enabling a high electrical output per unit volume, effective heat dissipation, and enhanced crash characteristics with minimal weight, thereby increasing the vehicle's range and power density.
Implementation Method 1
Each of these cooling hollow profiles has a cooling channel for a cooling fluid running parallel to the longitudinal axis of the battery cells, and each cooling hollow profile is designed in such a way that its outer contact surfaces lie against the lateral surfaces of battery cells, in particular against at least three battery cells and can therefore dissipate heat from at least three battery cells
Data Source
Figure 1a~2
Figure 3a~4
Figure 5~6
AI summary
The invention relates to a battery module with a plurality of cylindrical battery cells, particularly for motor vehicles. This new battery module has a metallic cooling structure formed by several metallic cooling profiles 20. Each of these cooling profiles 20 has a cooling channel 21 extending parallel to the longitudinal axis of the battery cells for a cooling fluid, and each cooling profile 20 is designed such that its outer contact surfaces 22 bear against the outer surfaces of the battery cells. Advantageously, the cooling profiles 20 are arranged between the battery cells in such a way as to result in a high packing density of the battery cells in the battery module.