Battery Module Heat Transfer Structure for High-Load Cooling
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Solution Overview
Problem
Large-sized battery modules face challenges in heat dissipation, leading to performance deterioration and increased risk of explosion or ignition, especially under high-temperature conditions and rapid charging scenarios, due to inadequate cooling structures.
Innovation Solution
A battery module design incorporating a first heat transfer member with a thermal conductive resin layer and a second heat transfer member, which is a thermally conductive and soft silicon-based foam pad, positioned to contact the battery cell stack and electrode leads, enhancing heat dissipation and stability by sequential heat transfer and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to increase capacity and output, then high power and large capacity are achieved, but heat dissipation becomes difficult and temperature rises excessively
Solution Approach 1:
The cooling plate is divided into multiple segments corresponding to different battery cell groups, allowing independent thermal management for each segment. This segmentation enables targeted heat dissipation from high-temperature regions while maintaining overall system efficiency.
Solution Approach 2:
Different regions of the cooling plate are designed with different thermal conductivities and geometries to match the local heat generation characteristics of underlying battery cells. High-heat-generation areas receive enhanced cooling through increased plate thickness or improved thermal contact, while lower-heat areas use standard configuration.
2Temperature
If heat dissipation material is applied to improve cooling performance, then heat dissipation is enhanced, but structural reasons may prevent proper application and battery cell damage may occur
Solution Approach 1:
A thermal interface material layer is introduced between the cooling plate and battery cells to ensure uniform heat distribution and prevent localized overheating. This intermediary layer compensates for surface irregularities and ensures reliable thermal contact without requiring direct metal-to-cell contact.
Solution Approach 2:
The cooling plate utilizes composite material construction combining high-thermal-conductivity materials with structurally stable materials. This composite approach enables effective heat dissipation while maintaining mechanical stability and preventing battery cell damage from thermal or structural stress.
3Volume of moving object
If battery cells are arranged in a compact stack to reduce size and weight, then integration density increases, but heat accumulation in narrow space accelerates temperature rise
Solution Approach 1:
The cooling system extends the heat dissipation path from two-dimensional surface contact to three-dimensional volumetric cooling by incorporating cooling channels and thermal conduits that penetrate through the battery stack. This dimensional transition enables efficient heat removal from internal cell regions without increasing external module dimensions.
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 solution effectively addresses heat generation issues, improves stability, and minimizes damage from vibrations, ensuring efficient cooling and safety of the battery module under high current and rapid charging conditions.
Implementation Method 1
a first heat transfer member and a second heat transfer member which is formed on an outer shell portion of the first heat transfer member, wherein the first heat transfer member includes a thermal conductive resin layer
Implementation Method 2
a second heat transfer member, which is a thermally conductive and soft silicon-based foam pad
Implementation Method 3
a second heat transfer member, which is a thermally conductive and soft silicon-based foam pad
Data Source
AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked, a module frame that surrounds the battery cell stack, and a first heat transfer member and a second heat transfer member located on the bottom portion of the module frame, wherein the second heat transfer member is formed on an outer shell portion of the first heat transfer member.