Battery Module Unit Sheet for Heat Dissipation
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Solution Overview
Problem
Current battery modules face challenges in heat radiation efficiency and manufacturing efficiency, leading to potential heat accumulation, cell imbalance, and decreased performance due to high-density packing and complex manufacturing processes.
Innovation Solution
A battery module design featuring a cell assembly with integrated unit sheets that surround secondary batteries, incorporating electric insulating materials, uneven structures for enhanced heat radiation, and a heat sink, along with adhesive members and heat conductive components to improve heat dissipation and manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple secondary batteries are densely packed in a small space to increase capacity, then energy density is improved, but heat dissipation becomes difficult and heat accumulation occurs
Solution Approach 1:
The battery module is divided into multiple unit bodies, each containing a limited number of secondary batteries (2-4 batteries per unit body). This segmentation allows each unit to be independently managed for heat dissipation while maintaining high overall capacity. The modular structure enables better thermal management compared to dense packing without division.
Solution Approach 2:
A unit sheet is introduced as an intermediary component between secondary batteries within each unit body. This unit sheet serves multiple functions: it provides thermal pathways for heat dissipation, maintains proper spacing between batteries, and facilitates modular assembly. The unit sheet acts as a mediator that enables both high density and effective heat management.
2Ease of manufacture
If multiple secondary batteries are stacked and arranged manually during manufacturing, then assembly is flexible, but manufacturing time increases and efficiency decreases
Solution Approach 1:
The manufacturing process is segmented into standardized unit body assemblies. Each unit body is pre-assembled with a specific configuration of 2-4 secondary batteries on a unit sheet, creating modular building blocks. This segmentation enables parallel manufacturing of multiple unit bodies simultaneously, significantly improving productivity while maintaining assembly flexibility through standardized interfaces.
Solution Approach 2:
Unit bodies are pre-assembled with secondary batteries arranged in predetermined configurations before final module assembly. This preliminary action of creating standardized unit bodies with built-in thermal management structures enables faster final assembly and reduces manufacturing complexity. The pre-arranged unit sheets with electrodes and thermal pathways are ready for efficient integration.
3Temperature
If secondary batteries are arranged with complex spacing and positioning structures, then heat dissipation and accessibility are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The unit sheet is designed as a universal multi-functional component that simultaneously provides: (1) thermal management pathways for heat dissipation, (2) structural support and positioning for secondary batteries, (3) electrical insulation, and (4) modular assembly interface. This multi-functionality eliminates the need for separate complex spacing and positioning structures, reducing overall device complexity while maintaining effective heat radiation.
4Ease of manufacture
If pouch type secondary batteries are handled during stacking and arranging, then manufacturing cost is low, but workability decreases and damage risk increases due to smooth outer surface
Solution Approach 1:
Secondary batteries are pre-arranged in standardized configurations on unit sheets with predetermined positioning features before handling and assembly. This preliminary arrangement with built-in positioning structures prevents slipping and misalignment during handling, improving workability without changing the pouch battery design or increasing manufacturing cost.
Solution Approach 2:
The unit sheet acts as an intermediary carrier that provides friction and grip surfaces for handling pouch-type secondary batteries. By placing batteries on the unit sheet with textured or adhesive surfaces, the smooth pouch surfaces are compensated for, preventing drops and arrangement disruptions during manufacturing while maintaining the cost-effective pouch battery design.
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 effectively prevents pouch damage, enhances heat radiation, reduces manufacturing costs, and increases efficiency by ensuring close adherence and improved heat dissipation, thereby extending battery life and performance.
Implementation Method 1
a heat sink (160) positioned at a bottom portion of the at least one unit body (120E)
Implementation Method 2
heat radiation efficiency are effectively improved
Implementation Method 3
heat conductive glue or heat conductive pad may be disposed between the integrated unit sheet and the at least two secondary batteries
Data Source
AI summary
Provided is a battery module in which a heat radiation effect and manufacturing efficiency are effectively improved. The battery module includes a cell assembly including at least one unit body, each unit body including at least two secondary batteries stacked in a first direction. Each unit body includes an integrated unit sheet folded to surround a top portion, a left surface, a right surface, and a bottom portion of the at least two secondary batteries, opposite ends of a top portion of the integrated unit sheet being positioned to contact each other on any one of the top portion, the left surface, the right surface, and the bottom portion of the at least two secondary batteries, and an electric insulating material coated on at least a part of a perimeter portion of the integrated unit sheet.