Battery Module with Thermally Conductive Case for Heat Dissipation
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Solution Overview
Problem
Conventional battery modules face challenges in maintaining a standard-sized prismatic structure with sufficient mechanical strength and effective cooling, particularly with pouch-shaped batteries, which have low mechanical strength and difficulty in retaining a rigid rectangular shape, leading to issues with heat dissipation and potential safety hazards.
Innovation Solution
A battery module design featuring a rectangular parallelepiped battery cell stack with a thermally conductive first module case and an electrically insulative second module case, allowing for efficient heat dissipation and improved mechanical stability without additional members, utilizing a pouch-shaped battery cell structure that can be easily assembled to form a standard-sized prismatic module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If pouch-shaped battery cells are used to reduce weight and manufacturing cost, then weight to capacity ratio is improved and manufacturing cost is reduced, but mechanical strength is insufficient and rigid rectangular parallelepiped shape cannot be retained
Solution Approach 1:
The patent combines pouch-shaped battery cells with a rigid frame structure made of metal or rigid plastic. The frame provides mechanical strength and maintains the rectangular parallelepiped shape, while the pouch-shaped battery cells inside provide the energy storage function with low weight. This composite structure resolves the contradiction by integrating materials with different properties - the rigid frame compensates for the weak mechanical strength of pouch cells while maintaining their weight advantage.
2Ease of manufacture
If pouch-shaped battery cells are used instead of can type cells, then manufacturing cost is reduced and shape flexibility is improved, but difficulty in retaining standard-sized prismatic structure increases
Solution Approach 1:
The patent uses the flexible pouch-shaped battery cells as the energy storage component while enclosing them in a rigid external frame that defines the standard prismatic shape. The pouch cells can be easily manufactured and inserted into the frame, while the frame itself provides the standardized external dimensions required for industry compatibility. This separates the manufacturing advantage of pouch cells from the shape requirement.
3Strength
If additional rigid parts are added to surround pouch-shaped batteries to maintain structure, then mechanical strength is improved and standard size is retained, but device complexity increases
Solution Approach 1:
The rigid frame structure serves multiple functions simultaneously: it provides mechanical strength to maintain the rectangular shape, defines the standard prismatic dimensions for industry compatibility, and acts as the outer housing for the battery module. By making the frame multi-functional, the patent avoids adding separate components for each function, thereby reducing overall device complexity while achieving structural stability.
4Ease of manufacture
If conventional battery module structures are used, then manufacturing simplicity is maintained, but cooling efficiency is insufficient and heat dissipation is poor
Solution Approach 1:
The patent incorporates thermally conductive materials specifically at the locations where heat generation is highest - namely, thermal pads between battery cells and the frame, and thermally conductive coatings on internal surfaces. This localized application of thermal management features provides effective cooling where needed most while maintaining manufacturing simplicity and avoiding the need for complex cooling systems throughout the entire module.
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 enhances safety and stability by providing effective heat dissipation and maintaining a standard-sized prismatic structure, improving production efficiency and cooling efficiency while minimizing the risk of thermal issues and mechanical failure.
Implementation Method 1
a first module case bent to surround two relatively large major surfaces of the battery cell stack and one surface of the battery cell stack opposite to the surface of the battery cell stack at which the electrode terminals of the battery cells are disposed, among six surfaces of the battery cell stack and a surface, the first module case being made of a thermally conductive material that is capable of dissipating heat generated from the battery cells during charge and discharge of the battery cells
Data Source
AI summary
Disclosed herein is a battery module including a battery cell stack configured to have a rectangular parallelepiped structure in which two or more plate-shaped battery cells, each of which has electrode terminals formed at one side thereof, are stacked and a breadth of one surface of the battery cell stack at which the electrode terminals of the battery cells are disposed is smaller than a width and a height of each major surface of the battery cell stack, a first module case bent to surround two relatively large major surfaces of the battery cell stack and one surface of the battery cell stack opposite to the surface of the battery cell stack at which the electrode terminals of the battery cells are disposed, among six surfaces of the battery cell stack and a surface, the first module case being made of a thermally conductive material that is capable of dissipating heat generated from the battery cells during charge and discharge of the battery cells, and a second module case bent to surround side surfaces of the battery cell stack adjacent to the two major surfaces of the battery cell stack and the surface of the battery cell stack at which the electrode terminals of the battery cells are disposed, the second module case being fastened to the first module case, the second module case being provided with through holes, through which the electrode terminals of the battery cells protrude outward, the second module case being made of an electrically insulative material.