Battery Module Cooling Spacer and Adhesive Design
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Solution Overview
Problem
Existing battery modules face challenges with cooling performance deviation and mechanical reliability, leading to potential overheating, reduced lifespan, and increased risk of explosion or ignition due to inadequate heat dissipation and structural instability.
Innovation Solution
A battery module design featuring a module frame that houses sub-modules with adhesive members and cooling spacers, allowing for improved cooling efficiency and structural stability through direct coolant contact and enhanced mechanical support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are stacked to form a large-capacity battery module, then high output is achieved, but heat dissipation becomes difficult and temperature rises excessively
Solution Approach 1:
The battery module is divided into multiple sub-modules, each with its own cooling chamber and coolant flow path. This segmentation allows heat from each sub-module to be dissipated independently, preventing heat accumulation in the entire module while maintaining high overall output capacity.
Solution Approach 2:
A coolant is introduced as an intermediary substance that absorbs heat from the battery cells through cooling chambers and cooling fins. The coolant circulates through the system, transferring heat from the battery cells to the external environment, thereby enabling effective heat dissipation while maintaining high power output.
2Quantity of substance
If battery cells are tightly arranged to increase energy density, then capacity is improved, but cooling performance becomes non-uniform and mechanical reliability decreases
Solution Approach 1:
Cooling chambers are provided between adjacent sub-modules with different cooling structures tailored to local heat generation patterns. The cooling fins and coolant flow paths are designed to match the specific thermal characteristics of each region, ensuring uniform cooling performance across the entire battery module while maintaining high cell density.
Solution Approach 2:
Cooling fins extend in the vertical direction (z-axis) between battery cells, adding a third dimension to the cooling structure. This three-dimensional cooling approach improves coolant flow distribution and heat dissipation uniformity across densely packed cells without compromising mechanical reliability.
3Stability of the object's composition
If adhesive members are used to secure battery cells to the module frame, then mechanical stability is improved, but coolant flow paths are blocked and cooling performance decreases
Solution Approach 1:
The adhesive application area is segmented and restricted to specific regions that do not interfere with coolant flow paths. By carefully positioning adhesive members away from critical cooling channels, both mechanical stability and cooling efficiency are maintained simultaneously.
Solution Approach 2:
Adhesive members are applied locally at specific positions on the module frame where they provide mechanical support without obstructing coolant flow. This localized adhesive application strategy ensures structural stability while preserving unobstructed cooling paths for optimal thermal management.
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 enhances cooling performance and mechanical reliability, reducing the risk of overheating and improving safety by ensuring effective heat dissipation and structural integrity.
Implementation Method 1
an adhesive member 800 is located on one surface (-z-axis direction) of the battery cell stack 120
Implementation Method 2
a cooling spacer 280 is provided between the plurality of battery cells 110
Implementation Method 3
a coolant such as insulating oil may be injected into the long module to directly cool the battery cells
Data Source
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AI summary
A battery module according to the present disclosure includes: at least one sub-module that comprises a battery cell stack in which a plurality of battery cells are stacked, and a busbar assembly containing a busbar electrically connected to the battery cell stack and a busbar frame covering the battery cell stack from at least one side, respectively; a module frame in which at least one of the sub-module is housed; and a fixing frame that is located while covering at least one surface of the battery cell stack.