Battery Module Direct Liquid Cooling With Leak-Safe Terminal Sealing
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Solution Overview
Problem
Existing battery modules using indirect water cooling methods face limitations in cooling performance due to indirect contact with battery cells, leading to increased volume and reduced energy density, and require a solution to prevent leakage of insulating cooling liquids.
Innovation Solution
A battery module design that introduces insulating cooling liquid directly into the module housing to contact electrode leads, bus bars, and inner terminals, utilizing a leakage prevention structure with sealing members and terminal assemblies to prevent leakage, while optimizing the flow path structure for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If indirect water cooling is used, then the cooling structure is simple, but the cooling performance is limited and volume increases
Solution Approach 1:
The patent merges the cooling function directly into the module housing by forming cooling channels within the housing structure itself, eliminating the need for separate external cooling devices. This integration allows cooling liquid to directly contact battery cells while maintaining structural simplicity.
Solution Approach 2:
The patent introduces an insulating cooling liquid as an intermediary substance that enables direct cooling while preventing electrical conduction. This mediator allows the cooling liquid to contact conductive components (bus bars, electrode leads) directly without causing short circuits, resolving the contradiction between direct cooling and electrical safety.
2Reliability
If indirect water cooling is used, then electrical safety is maintained, but energy density decreases due to increased volume
Solution Approach 1:
The insulating cooling liquid serves as a dual-function intermediary: it provides direct thermal contact for efficient cooling while simultaneously maintaining electrical insulation. This eliminates the need for additional safety barriers or larger housing dimensions, preserving energy density.
Solution Approach 2:
The cooling liquid performs multiple functions simultaneously: heat transfer medium, electrical insulator, and space filler. This multi-functionality allows direct cooling without compromising electrical safety or increasing volume, thereby maintaining high energy density.
3Ease of operation
If a perforated sealing plate is used for terminal connection, then electrical connection is enabled, but leakage risk increases
Solution Approach 1:
The insulating cooling liquid acts as a mediator that allows the sealing plate to be perforated for terminal access while preventing leakage through its insulating properties. The liquid fills the perforation pathways, creating a liquid seal that prevents gas or liquid leakage while maintaining electrical connectivity.
Solution Approach 2:
The patent changes the physical state or properties of the sealing system by introducing the insulating cooling liquid. The liquid's presence in the perforated regions creates capillary sealing effects and maintains pressure balance, preventing leakage while allowing terminal penetration.
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 design achieves efficient and rapid cooling of battery modules, preventing leakage and ensuring accurate temperature measurement, thereby enhancing cooling efficiency and energy density.
Implementation Method 1
an insulating cooling liquid flowing into a module housing to cool a battery cell directly contact with at least an electrode lead and a bus bar of the battery cell to cause efficient cooling
Data Source
AI summary
A battery module includes a sub module including a cell stack assembly having a plurality of battery cells; a module housing configured to accommodate the sub module; a front sealing plate configured to cover an opening at one longitudinal side of the module housing and having an inlet through which a cooling liquid is introduced; a rear sealing plate configured to cover an opening at the other longitudinal side of the module housing and having an outlet through which the cooling liquid is discharged; and a pair of terminal assemblies. The pair of terminal assemblies include an outer terminal located at an outer side of the front sealing plate, a stud inserted into a terminal hole formed in the front sealing plate, and a terminal spacer interposed between an inner surface of the terminal hole and the stud.