Battery Module Coupling Mechanism for Vibration and Thermal Management
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Solution Overview
Problem
Lithium-ion secondary battery modules face challenges in achieving a rigid construction with excellent heat dissipation properties without increasing the number of components, particularly in on-vehicle applications where mechanical vibrations and temperature variations are prevalent, leading to potential rattling and reduced lifespan.
Innovation Solution
A battery module design featuring insulating battery supports with a coupling mechanism that contracts in the stacking direction, sandwiched between regulating plates, allowing for intimate contact and secure stacking while minimizing component count, and incorporating a structure for coolant passage to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If battery supports are stacked without a case, then heat dissipation property is improved, but construction rigidity deteriorates causing rattling under vibrations and temperature variations
Solution Approach 1:
The battery module construction is divided into multiple battery supports, each containing a specific number of cells. This segmentation allows for improved heat dissipation by exposing more battery support surfaces while maintaining structural integrity through the modular arrangement of multiple supports stacked together.
Solution Approach 2:
A coupling part is introduced as an intermediary component between adjacent battery supports. This coupling part includes a projection from one battery support fitting into a depression of another, creating a mechanical connection that prevents rattling and ensures construction rigidity without requiring a full enclosing case.
2Stability of the object's composition
If the number of components is increased to ensure rigid construction, then construction rigidity is improved, but cost and volume energy density deteriorate
Solution Approach 1:
The coupling part is designed to be integrated with the battery supports themselves, with the projection and depression formed as part of the battery support structure. This merging eliminates the need for separate coupling components, reducing the total number of parts while maintaining construction rigidity.
Solution Approach 2:
The battery supports serve multiple functions: they provide structural containment for cells, act as thermal management surfaces for heat dissipation, and incorporate coupling features for mechanical connection. This multi-functionality reduces the need for additional specialized components.
3Reliability
If battery supports are made of insulating material, then electrical safety is improved, but thermal conduction deteriorates affecting heat dissipation
Solution Approach 1:
Different regions of the battery support are designed with different thermal properties. The portions requiring electrical insulation maintain insulating material properties, while the surfaces requiring heat dissipation are configured to maximize thermal exchange with the surrounding cooling medium, creating local optimization of both electrical safety and 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 effectively prevents rattling under vibrations and temperature-induced expansion/contraction, maintains high energy density, and ensures efficient heat dissipation, thereby extending battery life and performance in demanding applications.
Implementation Method 1
a coupling part that is located between the face of one of the battery supports and the face of another one of the battery supports adjacent to the one battery support, and contracts in the stacking direction when the battery supports are stacked so as to bring the faces of the battery supports into intimate contact with each other
Implementation Method 2
a first cooling passage that extends from one end of the group of cells to the other end of the group of cells in a state in which the coupling part is contracted, and allows a cooling liquid to flow, a second cooling passage that extends from one end of the group of cells to the other end of the group of cells
Implementation Method 3
a first cooling passage that extends from one end of the group of cells to the other end of the group of cells in a state in which the coupling part is contracted, and allows a cooling liquid to flow
Data Source
AI summary
A battery module includes a plurality of battery supports each having a face orthogonal to the stacking direction, and a side face, the battery supports each containing a plurality of cells and being made of an insulating material, a coupling part that is located between the face of one battery support and the face of another adjacent battery support, and contracts in the stacking direction upon stacking the battery supports to bring the faces of the battery supports into intimate contact, a group of cells including the battery supports stacked with the coupling part being placed between the battery supports, a base plate, and first and second regulating plates placed facing each other in a standing position on the base plate, the first and second regulating plates sandwiching the group of cells arranged between the first and second regulating plates and stacked with the coupling part being contracted.