Battery Module Inner Case Pressing for Direct Heat Sink Cooling
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Solution Overview
Problem
Existing battery modules face inefficiencies in cooling battery cells due to increased distance between the cells and the heat sink, leading to potential deterioration, firing, or explosion, and the heat sink may deform under hydraulic pressure from refrigerant flow.
Innovation Solution
A battery module design that includes an inner case with cooling projections and through-holes, a heat sink with cooling projections, a pressing member, and coupling members to align and press the inner case closely against the heat sink, eliminating the need for a thermal interface material and reducing the distance for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a thermal interface material is installed between the inner case and the heat sink, then the assembly is simplified, but the distance between the battery cells and the heat sink increases, degrading cooling efficiency
Solution Approach 1:
The patent removes the thermal interface material from the system entirely. The inner case is designed with a pressing projection that directly contacts the heat sink, eliminating the need for thermal interface material and thereby maintaining minimal distance for efficient heat transfer while simplifying the assembly process.
2Temperature
If the inner case is pressed closely against the heat sink, then cooling efficiency is improved, but the heat sink may deform under hydraulic pressure from refrigerant flow
Solution Approach 1:
The pressing projection is designed with a specific contact area that distributes the hydraulic pressure locally on the heat sink. This localized pressure distribution allows the inner case to be pressed closely against the heat sink for efficient cooling while preventing excessive localized stress that would cause deformation.
3Temperature
If the distance between the battery cells and the heat sink is reduced, then cooling efficiency is improved, but the structural complexity increases
Solution Approach 1:
The pressing projection is integrated directly into the inner case structure, merging the cooling function with the structural housing. This integration achieves minimal distance between battery cells and heat sink for efficient cooling without adding separate components, thereby avoiding increased structural complexity.
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 cools battery cells by reducing the distance to the heat sink, preventing deformation, and enhancing the lifespan and durability of the heat sink, ensuring stable cooling performance.
Implementation Method 1
a heat sink disposed in the accommodation and installed between the inner case and one side wall of the outer case to cool the battery cells
Data Source
AI summary
A battery module may effectively cool the plurality of battery cells by using the heat sink. The battery module includes an outer case having an accommodation space therein; an inner case having a storage space therein, the inner case being in the accommodation space; a plurality of battery cells in the storage space; a heat sink in the accommodation space with the heat sink being between the inner case and one side wall of the outer case and configured to cool the battery cells; and a pressing part in the accommodation space and having at least a portion between the other side wall of the outer case, which is opposite to the one side wall, and the inner case. The pressing part is configured to press the inner case toward the heat sink.