Battery Module Recessed Upper Plate Cooling Design
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Solution Overview
Problem
Existing battery modules with U-shaped frames face inefficiencies in cooling performance due to non-uniform intervals between battery cells and the frame, which can lead to reduced cooling efficiency and structural stability.
Innovation Solution
A battery module design featuring a U-shaped frame with a recessed upper plate that increases the contact area with a thermally conductive resin layer, including a compression pad and recessed portions to minimize intervals and enhance fixing forces, thereby improving cooling performance and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the intervals between battery cells and the frame are maintained to be uniform and minimum, then cooling efficiency is improved, but manufacturing precision and structural stability deteriorate due to non-uniform intervals
Solution Approach 1:
The recessed portion is pre-formed in the upper plate before battery cell installation. This preliminary structural preparation ensures that when battery cells are placed, they automatically achieve the desired minimum interval with the frame, eliminating the need for post-adjustment and ensuring both cooling efficiency and manufacturing precision
Solution Approach 2:
The upper plate's thickness parameter is varied by creating a recessed portion, changing the vertical position of the upper plate surface. This parameter change allows the upper plate to accommodate battery cells at the optimal minimum interval while maintaining uniformity across all cells, resolving the contradiction between cooling efficiency and manufacturing precision
2Temperature
If the contact area between battery cell stack and thermally conductive resin layer is increased, then cooling performance is improved, but resin usage and device complexity increase
Solution Approach 1:
The recessed portion is pre-formed in the upper plate to create optimal contact conditions between the battery cell stack and thermally conductive resin layer. This preliminary structural preparation ensures maximum contact area is achieved through the pressing action, improving cooling performance while minimizing the total resin quantity needed compared to a flat plate design that would require more resin to achieve the same contact pressure distribution
Solution Approach 2:
The upper plate geometry is modified by creating a recessed portion, changing the pressure distribution parameter. This causes the pressing force to be concentrated on the battery cell stack, increasing contact pressure and contact area with the thermally conductive resin layer, thereby improving cooling performance while using less resin material
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 minimizes intervals between battery cells and the frame, enhances fixing forces, reduces resin usage, and improves cooling efficiency, leading to improved structural stability and competitiveness.
Implementation Method 1
a thermally conductive resin layer formed between the battery cell stack and a bottom surface of the U-shaped frame
Data Source
AI summary
A battery module for enhancing cooling performance, and a battery pack including the same may include a battery cell stack, in which a plurality of battery cells are stacked, a U-shaped frame accommodating the battery cell stack and having an opened upper portion, an upper plate covering the battery cell stack on the opened upper portion of the U shaped frame, and a thermally conductive resin layer formed between the battery cell stack and a bottom surface of the U-shaped frame, and the upper plate may include a recessed portion formed to be recessed in a direction in which the battery cell stack is located, and a battery pack including the same.