EV Battery Module Housing With Conductive Gap Filling for Thermal Control
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Solution Overview
Problem
High-voltage batteries for electric vehicles face inefficiencies in temperature control due to limited cooling methods, which can lead to suboptimal performance at low ambient temperatures and increased manufacturing complexity.
Innovation Solution
A battery module design featuring thermally conductive medium-filled gaps between the battery cell package and the housing, utilizing a distribution channel and spraying point to ensure efficient heat transfer without excessive pressure on the cells, allowing for multi-sided temperature control and simplified, cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cooling is implemented only on one side by separate cooling channels outside the battery modules, then the cooling system is simple to manufacture, but the temperature control efficiency is insufficient
Solution Approach 1:
The patent transitions from one-sided cooling to multi-sided cooling by introducing cooling channels on multiple surfaces of the battery module housing. This dimensional expansion enables heat to be extracted from multiple directions simultaneously, significantly improving temperature control efficiency while maintaining manufacturing feasibility through standardized housing design
Solution Approach 2:
The battery module housing serves dual functions: it provides structural containment for the battery cells and simultaneously acts as a heat dissipation system through integrated cooling channels. This multi-functionality eliminates the need for separate external cooling apparatus, maintaining manufacturing simplicity while achieving efficient multi-sided cooling
2Temperature
If a thermally conductive medium is introduced into the gap between the battery cell package and the housing, then thermal contact with the entire surface is improved, but high pressure may damage the battery cells
Solution Approach 1:
The patent carefully controls the viscosity and thermal conductivity parameters of the introduced medium, selecting materials that provide optimal thermal contact without requiring excessive pressure for distribution. The medium's rheological properties are optimized to achieve uniform surface contact at pressures safe for battery cell integrity
Solution Approach 2:
The thermally conductive medium acts as an intermediary substance between the battery cell package and the housing structure. It fills gaps and irregularities in the contact surfaces, creating uniform thermal contact without transmitting damaging mechanical pressures to the battery cells, thus mediating between thermal requirements and mechanical constraints
3Temperature
If a highly viscous thermally conductive medium is used, then thermal conductivity is improved, but the medium cannot be introduced easily into the battery module
Solution Approach 1:
The patent incorporates distribution channels directly into the housing structure before battery cell installation. These pre-formed channels provide guided pathways that facilitate the introduction of viscous thermally conductive medium, allowing the medium to be pumped or poured through controlled routes without requiring high pressure or complex injection equipment
Solution Approach 2:
The patent utilizes hydraulic or pneumatic principles to introduce the viscous thermally conductive medium through the distribution channels. By applying controlled fluid pressure through pumps or pressure vessels, the medium is forced through the channels and into the gap between the battery cells and housing, enabling easy introduction of high-viscosity materials without damaging the battery cells
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 cooling efficiency, reduces manufacturing costs, ensures high process safety, supports large-scale production, and extends battery cell service life while minimizing space requirements.
Implementation Method 1
Heat thus can be transferred optimally between the battery cells of the battery cell package and the battery module housing
Data Source
AI summary
A battery module (1) for an electric vehicle has battery cells (3) stacked behind one another to form a battery cell package (4) in a multipart battery module housing (2). An end plate (5) is on an end of the battery cell package (4). The battery module housing (2) has a central portion (6) and a housing end plate (7) at an end of the central portion (6). A gap (9) between the battery cell package (4) and an inner surface of the central portion (6) is filled with a thermally conductive medium. The end plate (5) has a spraying point (11) for introducing the thermally conductive medium and a distribution channel (10) for guiding the thermally conductive medium from the spraying point (11) into spaces between the battery cell package (4) and the inner surface of the central portion (6).