Layered Battery Module Layout for Higher Cell Density Cooling

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Solution Overview

Problem

Conventional battery modules have a low energy density due to the inclusion of non-electricity storage components like heat sinks, which occupy space and reduce the packing efficiency of battery cells.

Innovation Solution

The battery module design incorporates a layered arrangement of battery cells with a unique exterior body structure that includes bent peripheries and extensions, a thermal conductor, and a water jacket to optimize space usage and thermal management, allowing for a thinner thermal conductive gel and increased cell density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heat sink and partition members are included for thermal management, then thermal control is improved, but energy density deteriorates due to increased non-electricity storage components

Engineering Contradiction:

Improvethermal managementVSAvoidenergy density

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The patent merges the thermal management function into the exterior body structure itself. The exterior body includes a heat dissipation portion that directly contacts adjacent battery cells, eliminating the need for separate heat sink components. The partition member is integrated with the exterior body, combining structural support and thermal management functions in a single component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exterior body serves multiple functions: it provides structural support, acts as a partition member between adjacent battery cells, and includes heat dissipation portions for thermal management. This multi-functionality reduces the number of separate components needed, thereby improving energy density while maintaining thermal control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If conventional exterior body structure is used, then manufacturing is simple, but space utilization deteriorates leading to lower cell density

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcell density

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The exterior body includes bent portions with curved surfaces that conform to the shape of battery cells. These curved surfaces improve contact between the heat dissipation portions and adjacent battery cells, optimizing space utilization and thermal contact without complicating the manufacturing process.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Temperature

If thick thermal conductive gel is used for heat dissipation, then thermal conduction is improved, but volume is increased reducing energy density

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidmodule volume

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The patent replaces thick thermal conductive gel with a solid-state heat dissipation structure integrated into the exterior body. The heat dissipation portions are made of thermally conductive material that provides structural support while conducting heat, eliminating the need for bulky gel layers and reducing overall module volume.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances energy density by reducing the thickness of thermal conductive materials and efficiently managing heat, leading to a more compact and high-performance battery module.

Implementation Method 1

a thermal conductor (for example, a thermal conductor 50 described later) disposed at a position opposed to the first housing to sandwich the first extension of the first periphery between the thermal conductor and the first housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a temperature adjuster (for example, a water jacket 70 described later) that is disposed at a position opposed to the first extension so that the thermal conductor is provided between the temperature adjuster and the first extension, and that is able to adjust a temperature inside the battery module via the thermal conductor

Methodology Applied

Scientific EffectThermal exchange: Heat Exchanger

Data Source

PatentUS20230327252A1Battery module

Publication Date: 2023.10.12 HONDA MOTOR CO LTD

AI summary

An object is to provide a battery module with higher energy density. A battery module includes a plurality of battery cells each including a layered body and an exterior body, in which a first periphery of each of any general battery cells arranged in a layered direction of the layered bodies includes a first bend that is coupled to a first bottom surface formed on a circumference of the exterior body and that bends toward one side in the layered direction, anda first extension extending from the first bend toward the one side in the layered direction, andthe first extension includes a first region extending from the first bend to another end in the layered direction of the next battery cell, anda second region extending from the other end in the layered direction of the next battery cell toward the one side in the layered direction.