Low Profile Battery Module With Integrated Thermal Interface
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Solution Overview
Problem
Existing battery modules for electric vehicles face challenges in supporting flexible pouch type cells, ensuring reliable connections, and effective thermal management, particularly due to the complexity and weight of traditional solutions, which can lead to module failure and safety issues.
Innovation Solution
A battery module design featuring a linear array of unit cells with a clamping and encapsulation system using thermally conductive epoxy, combined with a slotted bus bar interconnection method and a printed circuit board for battery management, allowing for efficient thermal management and reduced parts count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heavy and expensive metal fins are used to extract heat from pouch cells, then thermal management is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the thermal management function with the structural support function by integrating heat sinks directly into the module housing that already supports the pouch cells. This eliminates the need for separate metal fins and reduces parts count while maintaining effective heat extraction from the cells.
Solution Approach 2:
The module housing serves multiple functions: it provides structural support for the flexible pouch cells, acts as a thermal management system through integrated heat sinks, and serves as the enclosure for the battery module. This multi-functionality reduces the overall parts count and complexity.
2Stability of the object's composition
If pouch type cells are stacked together to form a rigid module, then structural stability is improved, but thermal management becomes difficult due to flexible and uneven sides
Solution Approach 1:
The patent merges the thermal management surfaces with the structural side walls of the module. The heat sinks are formed as integral parts of the housing that contains the stacked pouch cells, creating a unified structure that provides both structural stability and thermal management capability.
Solution Approach 2:
The patent changes the physical state and geometry of the thermal management surfaces by forming them as rigid integrated heat sinks within the housing, transforming the flexible uneven sides into stable thermal interfaces that maintain consistent contact with the pouch cells.
3Quantity of substance
If a large number of unit cells are assembled into a module, then energy density is improved, but reliability of connections decreases due to increased complexity
Solution Approach 1:
The patent segments the battery system into modular units where groups of pouch cells are assembled into standardized battery modules. Each module contains a manageable number of cells with reliable connections, and multiple modules can be combined to achieve the required total energy density and capacity.
4Length of stationary object
If the battery module height is reduced to meet vehicle placement requirements, then vehicle integration is improved, but manufacturing complexity increases
Solution Approach 1:
The patent compensates for reduced height by increasing the planar dimensions (length and width) of the battery modules. The modules are designed with an extended footprint that allows them to meet vehicle integration requirements while maintaining adequate cell capacity and simplifying manufacturing through standardized low-profile configurations.
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 solution results in a compact, scalable, and safe battery module with improved thermal characteristics and reduced risk of failure, enabling efficient assembly and integration into electric vehicles with a low profile and high energy density.
Implementation Method 1
Thermal management of the unit cells is facilitated by using a thermally conductive epoxy material and by forming a thermal interface surface on at least one side of the module.
Implementation Method 2
Using compression reduces the thickness of the side walls and reduces packaging overhead by weight and by volume.
Data Source
AI summary
An arrangement of a battery module and a method for making this module are presented. An embodiment is comprised of a plurality of Lithium-ion pouch type unit cells stacked in a linear array. A lightweight frame structure compresses the unit cells and the cells are encapsulated with thermally conductive epoxy. A method of assembly constrains the unit cells during encapsulation such that a thin wall of epoxy is achieved, reducing the thermal resistance of the side walls. A slotted flat panel is placed over the unit cells and the cell tabs protrude through the panel. An arrangement of slotted bus bars reside on the flat panel and the cell tabs are bent at right angles in a manner that allows the tabs to be attached to the bus bars by a soldering or similar means. In an embodiment of the battery module, the flat panel contains battery management circuitry.