Battery Module With Integrated Cooling Case
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Solution Overview
Problem
The existing methods for forming battery modules or packs require numerous coupling elements and cooling devices, leading to increased manufacturing costs, volume, and weight, while also reducing output due to the added components.
Innovation Solution
A battery module design that incorporates a thermally conductive module case with a resin layer, allowing for efficient thermal dissipation and reduced need for coupling parts, featuring injection holes for resin injection and observation holes for ensuring material distribution, and a resin layer with high thermal conductivity and adhesion strength to immobilize battery cells effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coupling elements and cooling devices are used to form battery modules, then the battery module can be assembled and cooled, but the manufacturing cost, volume, and weight increase
Solution Approach 1:
The module case is designed to integrate both structural support and cooling functions into a single component. The case includes cooling channels formed directly within its structure, eliminating the need for separate cooling devices and coupling elements, thereby reducing weight while maintaining assembly and cooling capabilities.
Solution Approach 2:
The module case serves multiple functions simultaneously: it provides mechanical support for battery cells, acts as a thermal management system through integrated cooling channels, and serves as the structural housing. This multi-functionality eliminates the need for separate dedicated cooling devices and reduces overall component count and weight.
2Reliability
If coupling elements and cooling devices are used to form battery modules, then the battery module can be assembled and cooled, but the volume increases
Solution Approach 1:
The module case is designed to integrate both structural support and cooling functions into a single component. The case includes cooling channels formed directly within its structure, eliminating the need for separate cooling devices and coupling elements, thereby reducing volume while maintaining assembly and cooling capabilities.
Solution Approach 2:
The cooling channels are nested within the walls and structure of the module case itself, utilizing the existing structural volume for dual purposes. This nested design allows the cooling system to occupy no additional external volume beyond what is already required for the structural case.
3Reliability
If coupling elements and cooling devices are used to form battery modules, then the battery module can be assembled and cooled, but the manufacturing cost increases
Solution Approach 1:
The module case is designed to integrate both structural support and cooling functions into a single component. The case includes cooling channels formed directly within its structure, eliminating the need for separate cooling devices and coupling elements, thereby reducing part count, assembly steps, and manufacturing cost while maintaining assembly and cooling capabilities.
Solution Approach 2:
The module case serves multiple functions simultaneously: it provides mechanical support for battery cells, acts as a thermal management system through integrated cooling channels, and serves as the structural housing. This multi-functionality reduces the total number of components that need to be manufactured, procured, and assembled, thereby reducing manufacturing cost.
4Reliability
If coupling elements and cooling devices are used to form battery modules, then the battery module can be assembled and cooled, but the output for the volume and weight decreases
Solution Approach 1:
The module case is designed to integrate both structural support and cooling functions into a single component. By eliminating separate cooling devices and coupling elements, more of the total module volume and weight can be allocated to active battery cells, thereby increasing the power output relative to the total volume and weight.
Solution Approach 2:
The module case serves multiple functions simultaneously, reducing the proportion of volume and weight dedicated to auxiliary components. This increases the ratio of active energy-storing components to total system mass and volume, thereby improving power density and output for the given volume and weight.
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 results in a compact, lightweight battery module with enhanced thermal dissipation properties and high output, reducing the need for conventional coupling parts and cooling apparatus, thus achieving a smaller, lighter, and more efficient battery module.
Implementation Method 1
a resin layer with high thermal conductivity and adhesion strength
Data Source
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AI summary
Provided are a battery module, a method of manufacturing the same, and a resin composition applied to the method of manufacturing the same. A battery module manufactured with a simple process and low cost but having excellent output for the size thereof, a method of manufacturing the same, and a resin composition applied to the method of manufacturing the same are provided in the present invention.