Battery Module Housing with Integrated Cooling Ducts
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Solution Overview
Problem
High-voltage energy stores for electric vehicles require efficient cooling solutions, but existing cooling ducts are complex, expensive, and provide suboptimal cooling due to adhesive bonding and limited heat transfer.
Innovation Solution
A battery module design featuring a main component with integral housing surrounding battery cells from four sides and an additional component with recesses for temperature control, forming media-carrying ducts, where the main component is made of light metal and the additional component has lower thermal conductivity, allowing effective heat dissipation and simplified production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling ducts are used in the form of thin-walled extruded profiles, then cooling effect is provided, but production complexity increases and cost increases
Solution Approach 1:
The patent merges the cooling duct function with the battery module housing structure itself. The housing walls are designed with integrated cooling channels that directly contact the battery cells, eliminating the need for separate thin-walled extruded cooling ducts. This integration reduces production complexity while maintaining effective cooling through direct thermal contact.
2Temperature
If cooling ducts are pressed and/or adhesively bonded onto bulkhead plate or battery modules, then cooling is provided, but manufacturing complexity increases and cooling efficiency decreases
Solution Approach 1:
The cooling channels are integrated directly into the battery module housing structure, eliminating the need for separate pressing and adhesive bonding operations. The housing is designed as a single component that both contains the batteries and provides cooling pathways, simplifying manufacturing while improving thermal contact.
Solution Approach 2:
The patent extracts the cooling function from separate auxiliary components and embeds it directly into the housing structure. By taking out the cooling duct as a separate element and integrating its functionality into the housing walls, the design eliminates complex assembly steps while enhancing cooling efficiency through direct contact.
3Temperature
If cooling medium reaches battery modules only via walls of cooling ducts and adhesive film, then cooling is provided, but cooling effectiveness is reduced
Solution Approach 1:
The patent removes the adhesive film layer from the thermal path by integrating cooling channels that directly contact the battery cell surfaces. This extraction of the insulating adhesive layer eliminates an unwanted thermal resistance, allowing the cooling medium to transfer heat more effectively from the battery cells.
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
This design enhances cooling efficiency, reduces production costs and weight, while maintaining low space requirements, offering improved thermal management for high-voltage energy stores.
Implementation Method 1
The recesses are closed by connecting the additional component to the main component to form media-carrying ducts
Implementation Method 2
receiving a medium for temperature control
Data Source
AI summary
A battery module includes a battery module housing and a plurality of battery cells accommodated by the battery module housing. The battery module housing includes a main component for accommodating the battery cells and at least one additional component. The main component is of integral design and surrounds the battery cells from four sides. The additional component includes recesses for receiving a medium for temperature control. The recesses are closed by connecting the additional component to the main component to form media-carrying ducts. The main component is of open design on averted end sides. The battery cells are arranged at least substantially within the space which is surrounded by the main component.