Cylindrical Battery Module Assembly With Serpentine Cooling and Venting
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Solution Overview
Problem
The current CTP structure for cylindrical battery cells faces challenges such as a complicated assembly process, difficulty in glue potting, and limited repairability, particularly due to the large number of individual cells and potential thermal runaway issues.
Innovation Solution
A battery module design featuring a housing with integrated side and end plates, a fixing bracket with positioning grooves, a serpentine cooling plate, and a cell contact system, which simplifies assembly, positions cells effectively, and includes an exhaust channel for thermal runaway safety, allowing modular repair and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of cylindrical battery cells are arranged in groups to form a battery pack using CTP structure, then the energy density is improved, but the assembly process becomes complicated and glue potting becomes difficult
Solution Approach 1:
The patent divides the battery pack into multiple independent modules, each containing a subset of battery cells. This segmentation allows for simplified assembly processes where each module can be independently manufactured and assembled, rather than handling all cells simultaneously in a single complex assembly operation.
Solution Approach 2:
The patent introduces a module housing as an intermediary structure that contains and organizes battery cells within each module. This housing serves as a mediator between the individual cells and the overall battery pack assembly, simplifying the gluing and assembly processes by providing a pre-organized structure.
2Stability of the object's composition
If the entire battery pack is potted with glue to secure battery cells, then the structural stability is improved, but the manufacturing difficulty and time consumption increase
Solution Approach 1:
The patent applies glue potting at the module level rather than the entire battery pack level. Each module housing contains a subset of cells that are potted together independently, which significantly reduces the time and complexity of the gluing process compared to potting all cells in one large batch.
Solution Approach 2:
The patent performs glue potting on individual modules before final battery pack assembly. This preliminary action allows for more efficient and controlled application of adhesive on smaller, more manageable structures, improving overall manufacturing efficiency.
3Reliability
If a single cylindrical battery cell has a quality problem in CTP structure, then the battery pack must be disassembled for repair, but this reduces repairability and increases maintenance complexity
Solution Approach 1:
The patent organizes battery cells into modular groups where each module can be independently accessed and replaced. If a single cell or a small group of cells has quality issues, only the affected module needs to be disassembled and replaced, rather than disassembling the entire battery pack.
Solution Approach 2:
The patent enables easy replacement of faulty modules by designing the module structure to be independently removable. When a module develops quality issues, the entire module can be quickly replaced as a unit, improving repair efficiency and reducing maintenance complexity.
4Strength
If the battery pack is designed as a single integrated unit, then the structural integrity is improved, but the thermal management and safety during thermal runaway become more difficult
Solution Approach 1:
The patent divides the battery pack into multiple modules with individual housings, creating physical separations between cell groups. This segmentation limits the propagation of thermal runaway to contain it within a single module, preventing it from affecting the entire battery pack while maintaining overall structural integrity through the modular housing design.
Solution Approach 2:
The patent extracts and isolates individual modules within the battery pack structure, creating independent compartments for each module. This extraction allows thermal issues to be contained within specific modules rather than affecting the entire pack, improving safety while maintaining structural coherence.
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
Facilitates a simpler manufacturing process, improves safety through thermal management and modular maintenance, and reduces the complexity of glue potting, enabling large-scale production and efficient repair of individual faulty cells.
Implementation Method 1
A serpentine cooling plate is disposed between two rows of cylindrical battery cells
Implementation Method 2
A serpentine cooling plate is disposed between two rows of cylindrical battery cells
Implementation Method 3
an exhaust channel is formed between the fixing bracket and the bottom plate, and the exhaust channel communicates with the positioning grooves
Implementation Method 4
at least one of the two end plates on the two sides of the bottom plate is provided with an exhaust slot, and the exhaust slot communicates with the exhaust channel
Data Source
AI summary
A battery module and a battery pack are provided. A battery module, includes a housing, comprising a bottom plate, side plates, a top plate, and end plates, wherein the top plate is fixedly connected to the bottom plate, the side plates, and the end plates sequentially to enclose and form a containing cavity; a fixing bracket located in the containing cavity and mounted on the bottom plate; a battery cell stack, comprising cylindrical battery cells arranged in a plurality of rows, wherein a top portion of each of the cylindrical battery cells is provided with an electrode terminalcell; a cell contact system (CCS) component, disposed on a side of the battery cell stack close to the top plate, and electrically connected to the electrode terminals of the cylindrical battery cells; and a serpentine cooling plate disposed between two rows of cylindrical battery cells.