Battery Module Heat Transfer Layers and Fluid Conduits
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Solution Overview
Problem
Conventional cooling systems for automotive battery assemblies in alternative fuel vehicles are costly and unreliable due to their complexity, leading to high manufacturing and maintenance costs, and they do not effectively manage heat generated during charge and discharge processes, which can adversely affect battery performance.
Innovation Solution
A battery module design featuring stacked battery cells with heat transfer layers and serpentine fluid conduits to efficiently transfer heat away from the cells, reducing the number of parts and improving temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling systems are used with multiple parts and seals, then cooling function is provided, but manufacturing and maintenance costs increase and reliability decreases
Solution Approach 1:
The patent integrates the cooling function directly into the battery cell structure by incorporating coolant channels within the cell housing or thermal management plates, merging the cooling system with the battery assembly itself. This eliminates separate cooling components and seals, reducing part count while maintaining effective heat dissipation.
Solution Approach 2:
The battery cell structure is designed to perform its own cooling function through integrated thermal management features, such as internal coolant channels or phase change materials embedded within the cell. This self-service approach eliminates the need for external cooling systems with multiple moving parts and seals.
2Ease of manufacture
If conventional cooling systems with multiple parts are used, then cooling function is provided, but manufacturing and maintenance costs increase
Solution Approach 1:
The cooling system is merged with the battery cell structure, allowing simultaneous manufacturing of both components. This integration reduces the total number of parts that need to be manufactured separately and assembled, thereby lowering overall manufacturing costs and simplifying the production process.
Solution Approach 2:
The battery cell housing or thermal management plates serve multiple functions: structural support, electrical insulation, and heat dissipation. This multi-functionality eliminates the need for separate dedicated cooling components, reducing part count and manufacturing complexity.
3Duration of action of moving object
If heat accumulates in the battery assembly, then battery operation continues, but battery performance deteriorates
Solution Approach 1:
The patent introduces coolant as an intermediary substance that absorbs heat from the battery cells and transports it to heat exchangers or external cooling systems. This intermediary mechanism effectively manages temperature without requiring direct contact between cooling components and battery cells, extending battery life through improved thermal management.
Solution Approach 2:
The patent may utilize phase change materials (such as phase change packs or latent heat storage materials) that absorb or release heat during phase transitions (solid-liquid or liquid-gas). This passive thermal regulation maintains battery temperature within optimal ranges, extending battery life without active cooling systems.
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 enhances cooling efficiency, reduces manufacturing and maintenance costs, and extends the life cycle of battery assemblies by effectively managing heat generated during operation, thereby improving battery performance and reliability.
Implementation Method 1
a first heat transfer layer arranged between the first battery cell and the second battery cell and a second heat transfer layer arranged between the second battery cell and the third battery cell
Implementation Method 2
a serpentine fluid conduit contacting the first heat transfer layer
Data Source
AI summary
A battery module includes first, second, and third stacked battery cells, the second battery cell being arranged between the first battery cell and the third battery cell. The battery module further includes a first heat transfer layer arranged between the first battery cell and the second battery cell and a second heat transfer layer arranged between the second battery cell and the third battery cell. The battery module may further include a fluid conduit coupled to the first heat transfer layer and the second heat transfer layer.