Battery Module Heat Sink for Electrical Connection Thermal Management

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Solution Overview

Problem

High-temperature heat generated during charge and discharge in battery modules, particularly at electrical interconnection regions, poses a risk of physical and chemical deformation, leading to reduced lifespan and safety concerns, especially in high-power applications like electric vehicles.

Innovation Solution

A battery module structure incorporating a heat sink mounted at electrical connection regions between unit cells and/or battery module connection members, utilizing high-thermal-conductivity materials and phase change materials to absorb and dissipate heat effectively, maintaining temperature within a safe range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are stacked with high integration to reduce size and weight, then productivity and weight-to-capacity ratio are improved, but heat dissipation becomes more difficult and temperature accumulates

Engineering Contradiction:

Improveintegration densityVSAvoidheat accumulation

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

A heat dissipation member made of high-thermal-conductivity material is introduced as an intermediary between battery cells to facilitate heat transfer. This mediator component enables effective heat dissipation while maintaining high integration density, resolving the contradiction between compact stacking and thermal management.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The thermal conductivity parameter of the interface between battery cells is enhanced by introducing heat dissipation members with high thermal conductivity. This parameter change allows heat to be efficiently conducted away from the stacked cells, enabling high integration without excessive heat accumulation.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If coolant channels are defined between stacked battery cells to remove heat, then temperature control is improved, but device complexity and pressure loss increase

Engineering Contradiction:

Improveheat removalVSAvoidcooling structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The complex coolant channel structure is extracted and replaced with simpler heat dissipation members that rely on thermal conduction rather than fluid flow. This extraction eliminates the need for complicated channel definitions and coolant circulation systems while maintaining effective heat removal.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical fluid flow system (coolant channels with pumping) is substituted with a thermal conduction system using high-thermal-conductivity materials. This replacement simplifies the cooling structure by eliminating complex fluid dynamics while achieving comparable or superior heat dissipation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If battery cells are arranged at predetermined intervals to facilitate heat removal, then temperature control is improved, but the overall size of the battery module increases

Engineering Contradiction:

Improveheat dissipationVSAvoidbattery module size

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

Heat dissipation capability is enhanced locally at critical interfaces between battery cells through the insertion of heat dissipation members. This localized quality improvement allows cells to be stacked closer together without compromising thermal management, thereby reducing overall module size while maintaining effective heat removal.

Inventive Principle:

Principle #3Local quality

4Temperature

If a fan is provided to prevent pressure loss in coolant channels, then heat removal efficiency is improved, but power consumption and device complexity increase

Engineering Contradiction:

Improveheat removal efficiencyVSAvoidpower consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The active mechanical cooling system (fan-driven coolant circulation) is replaced with a passive thermal conduction system using high-thermal-conductivity materials. This substitution eliminates the need for power-consuming fans while maintaining effective heat removal through material-based heat transfer.

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

The heat sink effectively controls temperature at electrical connection regions, preventing deformation and maintaining optimal module performance, thereby enhancing safety and lifespan while reducing the risk of overheating and explosion.

Implementation Method 1

a heat sink is mounted to electrical connection regions between the unit cells and/or to outsides of battery module connection members connected to the electrical connection regions

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10632848B2Battery module of improved safety

Publication Date: 2020.04.28 LG ENERGY SOLUTION LTD

AI summary

Disclosed herein is a battery module configured in a structure in which a plurality of battery cells or unit modules (‘unit cells’) are stacked, and a heat sink is mounted to electrical connection regions between the unit cells and/or to outsides of battery module connection members connected to the electrical connection regions.