Battery Module With High Thermal Conductivity Heatsink
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Solution Overview
Problem
High energy density battery cells in electric vehicles face thermal management challenges due to poor thermal conductivity, leading to potential thermal runaway, fire, and explosion risks, especially under vehicle shock and vibration, where existing cooling methods are ineffective and safety margins are compromised.
Innovation Solution
A battery module design with high thermal conductivity, featuring a mechanically robust housing that securely mounts battery cells with metal electrodes on top and bottom surfaces and a heatsink device for efficient heat dissipation, ensuring stable operation and preventing chain reactions during thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If forced air cooling or liquid cooling is used to manage battery thermal runaway, then cooling effectiveness is improved, but system reliability deteriorates under vehicle crash conditions
Solution Approach 1:
The battery module housing itself serves as the thermal management system through integrated heat dissipation fins and high thermal conductivity materials, eliminating dependence on external cooling systems that may fail during crashes. The structure passively dissipates heat through its geometric design and material properties.
Solution Approach 2:
The patent replaces active mechanical cooling systems (fans, pumps, liquid channels) with a passive thermal conduction system using high thermal conductivity materials and optimized geometric structures that dissipate heat without moving parts or fluid circulation.
2Ease of manufacture
If battery cells are mounted with poor thermal conduction, then manufacturing simplicity is improved, but thermal safety deteriorates
Solution Approach 1:
The battery module housing combines structural materials with high thermal conductivity materials to create a composite structure that simultaneously provides mechanical strength and efficient heat dissipation. The housing integrates thermal management functionality into its base material composition.
Solution Approach 2:
The patent adds thermal management functionality by incorporating heat dissipation fins that extend the housing structure into additional spatial dimensions, increasing surface area for heat radiation and convection while maintaining the core structural integrity.
3Quantity of substance
If battery cells are tightly packaged to increase energy density, then space utilization is improved, but thermal management capability deteriorates
Solution Approach 1:
The battery module housing performs multiple functions simultaneously: it provides structural support for tightly packed cells, serves as a thermal conduction pathway, and acts as a heat dissipation radiator through integrated fins, eliminating the need for separate thermal management components.
Solution Approach 2:
The patent merges the structural housing with the thermal management system by integrating heat dissipation fins directly into the housing structure, combining mechanical support and thermal dissipation functions into a single unified component.
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 enhances battery pack safety by preventing cell damage, prolonging operational life, and minimizing the risk of thermal runaway and explosions by providing effective heat dissipation and secure electrical connections, even under severe conditions.
Implementation Method 1
a high thermal conductivity battery module could dissipate the thermal energy from a runaway cell, lower the probability of fire and explosion, and minimize the thermal impact to adjacent cells
Implementation Method 2
anode/cathode sheets are constructed with metal with good thermal and electrical conductivity. The positive and negative connections are brought out in either the top plane or bottom plane in the same direction as the jelly roll
Data Source
AI summary
A battery module with high thermal conductivity and its assembling method are disclosed. The battery module includes multiple battery cells, a primary retaining frame, a secondary retaining frame, common electrodes and a heatsink device. The primary and second retaining frames are combined together to constitute accommodation chambers for housing the battery cells and formed with interference flanged to secure the battery cells in position. Upon being inserted into the accommodation chambers, the battery cells are electrically connected to the common electrodes. The heatsink device is then coupled to the primary retaining frame and/or the secondary retaining frame, such that the heatsink device abuts against the top common electrode and/or the bottom common electrode of the battery cells.