Battery Module Cooling Structure With Integrated Heat Sink

Solution Overview

Problem

Conventional battery modules and packs face challenges in effectively dissipating heat generated by a large number of stacked battery cells, leading to potential performance deterioration, shortened lifespan, and increased risk of explosion or ignition, particularly under high-temperature conditions.

Innovation Solution

A battery module design featuring a housing with a convex pattern portion on its bottom part that integrates with a heat sink, forming a direct refrigerant flow passage, and a thermal conductive resin layer with reduced thickness in patterned regions to enhance heat transfer and cooling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a large number of battery cells are stacked to form a battery module, then capacity and output are improved, but heat dissipation becomes more difficult and temperature rises more quickly

Engineering Contradiction:

Improvecapacity and outputVSAvoidheat dissipation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The housing bottom part and heat sink are merged into an integrated structure where the housing bottom part serves dual functions as both structural enclosure and heat dissipation component. The heat sink is formed by providing a recessed portion in the bottom part, eliminating the need for separate heat sink components and reducing thermal resistance interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A thermal conductive resin layer is introduced as an intermediary material between the battery cell stack and the housing bottom part/heat sink. This thermal conductive resin improves heat transfer efficiency from the battery cells to the heat sink structure, acting as an effective thermal mediator.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If conventional cooling structures with separate heat sinks are used, then cooling function is provided, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecooling functionVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The housing bottom part and heat sink are merged into an integrated structure where the housing bottom part serves dual functions as both structural enclosure and heat dissipation component. The heat sink is formed by providing a recessed portion in the bottom part, eliminating the need for separate heat sink components and reducing thermal resistance interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing bottom part is designed to perform multiple functions simultaneously: structural support, thermal conduction, and heat dissipation. By forming the heat sink directly within the bottom part structure, the same component serves both mechanical and thermal management purposes, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If conventional cooling structures with separate heat sinks are used, then cooling function is provided, but manufacturing cost increases

Engineering Contradiction:

Improvecooling functionVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The housing bottom part and heat sink are merged into an integrated structure where the housing bottom part serves dual functions as both structural enclosure and heat dissipation component. The heat sink is formed by providing a recessed portion in the bottom part, eliminating the need for separate heat sink components and reducing thermal resistance interfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing bottom part is designed to perform multiple functions simultaneously: structural support, thermal conduction, and heat dissipation. By forming the heat sink directly within the bottom part structure, the same component serves both mechanical and thermal management purposes, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If air gaps are present between housing and heat sink, then assembly tolerance is accommodated, but heat transfer efficiency decreases

Engineering Contradiction:

Improveassembly toleranceVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

A thermal conductive resin layer is introduced as an intermediary material between the battery cell stack and the housing bottom part/heat sink. This thermal conductive resin improves heat transfer efficiency from the battery cells to the heat sink structure, acting as an effective thermal mediator.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 integrated cooling structure improves heat dissipation, reduces module height, enhances space utilization, and reinforces rigidity, while minimizing air gaps and costs, thereby increasing the capacity and output of the battery pack.

Implementation Method 1

a thermal conductive resin layer with reduced thickness in patterned regions to enhance heat transfer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

forming a direct refrigerant flow passage

Methodology Applied

Scientific EffectHeat transfer: Heat Sink

Data Source

PatentUS12592424B2Battery module and battery pack including the same

Publication Date: 2026.03.31 LG ENERGY SOLUTION LTD

AI summary

A battery module including: a battery cell stack including a plurality of battery cells; a housing for housing the battery cell stack; and a heat sink located below a bottom part of the housing. The bottom part constitutes an upper plate of the heat sink, the heat sink and the bottom part form a flow passage for a refrigerant, and a convex pattern portion protruding in a direction in which the battery cell stack is located is formed on the bottom part.