Battery Module Thermal Management via Integrated Casing and Flexible Pre-load
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Solution Overview
Problem
Existing battery modules face challenges in efficient heat dissipation due to bulky designs, inefficient heat transfer, and increased manufacturing costs, particularly when dealing with lithium ion battery cells, which require effective thermal contact and flexible packaging materials to maintain safety and longevity.
Innovation Solution
A battery module design featuring a casing with integrated cell support structures and flexible members that exert pre-load pressure for gap-less thermal contact, combined with thermal interface members that soften at higher temperatures to prevent air entrapment, and a heat dissipating structure on the outer surface for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant channels are designed around individual battery cells, then heat dissipation is improved, but the device becomes bulky and manufacturing cost increases
Solution Approach 1:
The patent merges the heat dissipation function into the casing structure itself by integrating heat dissipating fins directly onto the casing. This eliminates the need for separate coolant channels around each cell, reducing device bulkiness while maintaining effective heat dissipation through the unified casing-based thermal management system.
2Temperature
If thermal contact between cells and casing is improved, then heat dissipation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs a flexible thermal interface material between the battery cells and the casing. This flexible material compensates for dimensional variations and manufacturing tolerances, ensuring consistent thermal contact without requiring high manufacturing precision. The flexibility allows the material to conform to surface irregularities and maintain reliable thermal coupling.
3Adaptability or versatility
If flexible packaging materials are used for thermal contact, then adaptability to cell variations is improved, but manufacturing precision may decrease
Solution Approach 1:
The patent utilizes the temperature-dependent softening property of the thermal interface material. At assembly temperature, the material is soft and flexible, allowing easy accommodation of cell size and shape variations without precise positioning. This parameter change with temperature enables high adaptability while minimizing the need for precise manufacturing and assembly tolerances.
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 ensures effective and safe heat dissipation, maintains thermal stability, and reduces manufacturing costs by eliminating the need for additional fasteners and adhesives, while accommodating variations in cell size and shape, ensuring durability and flexibility for different applications.
Implementation Method 1
a flexible member positioned between the second inner surface and one of the cell holders for exerting a pre-load pressure
Implementation Method 2
a thermal interface member positioned between the flexible member and one of the cell holders for thermally conducting heat generated by the plurality of cells
Implementation Method 3
a heat dissipating structure on the first outer surface for dissipating heat generated by the plurality of cells to external environment
Data Source
AI summary
A battery module includes cells positioned in cell holders and a casing. A cell support structure is integrated with a first inner surface of the casing for establishing a thermal contact between the cells and the first inner surface. Further, the battery module includes a flexible member positioned between a second inner surface of the casing and one of the cell holders for exerting pressure on the cell holders. A thermal interface member is in contact with at least one of the cell holders. The flexible member, the thermal interface member, and the cell support structure package the cells efficiently, making the battery module mechanically stable, impact resistant, and vibration proof.