Battery Module Side-Wall Cooling for Space-Limited Stack Thermal Control
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Solution Overview
Problem
Existing battery stack cooling systems, particularly in heavy-duty vehicles, face challenges in providing sufficient cooling due to limited space and inefficiencies in multilayer cell stack solutions, where traditional liquid cooling methods may not adequately address temperature control needs.
Innovation Solution
The integration of a liquid cooling system within the side walls of battery modules, featuring a groove in the supporting side walls covered by a cover plate, forming an integrated cooling system that allows for direct contact and increased surface area with battery cells while providing robust support and simplified cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional liquid cooling methods are used in battery packs, then cooling function is provided, but sufficient cooling is not achieved for demanding applications and space is wasted
Solution Approach 1:
The cooling plates are integrated directly into the supporting side walls of the battery modules, merging the structural support function with the thermal management function. This eliminates separate cooling components and achieves better cooling efficiency through direct thermal contact with the battery cells.
Solution Approach 2:
The cooling system transitions from traditional bottom-side cooling to side-wall cooling, utilizing the vertical dimension of the supporting side walls. The cooling plates are positioned at different heights along the side walls, creating multiple cooling zones that efficiently manage heat from stacked battery cells in the vertical direction.
2Productivity
If cooling plates are integrated into supporting side walls, then cooling efficiency is improved and space is optimized, but manufacturing complexity increases
Solution Approach 1:
The supporting side wall is divided into functional segments: the cooling plate portion with integrated cooling channels, and the connecting portions that link to adjacent battery modules. This segmentation allows the cooling plate to be manufactured as a modular component that can be precisely formed with cooling channels while maintaining structural integrity.
Solution Approach 2:
The supporting side wall geometry is modified to incorporate the cooling plate structure, changing the physical parameters of the side wall to include integrated cooling channels. This parameter change enables the side wall to serve dual functions structurally and thermally without requiring entirely separate components.
3Ease of manufacture
If cooling system components are separated, then manufacturing is easier, but device complexity increases and space is wasted
Solution Approach 1:
The cooling plates are merged with the supporting side walls, combining what would traditionally be separate components into a single integrated structure. This reduces the total number of parts, simplifies the cooling system architecture, and eliminates the need for additional mounting hardware and connections between separate cooling plates and supporting structures.
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
This solution enhances cooling efficiency, reduces component complexity, and allows for robust support of battery cells, enabling effective temperature management and improved performance in demanding applications.
Implementation Method 1
The first and/or the second supporting side wall comprise a liquid cooling channel, the liquid cooling channel being in the form of a groove provided in the first and/or second supporting side wall
Implementation Method 2
pumping coolant through pipes and plates built into the battery packs
Data Source
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AI summary
The present disclosure relates to a battery stack (1) for an electrified vehicle (2), the battery stack (1) comprising a cooling system (3), the battery stack (1) comprising a first and a second battery module (4,5), the battery stack extending in a height direction (y), a width direction (x) and a depth direction (z), each of the first and the second battery modules (4,5) comprising battery cells (6) being stacked in the depth direction (z), the first and the second battery modules (4,5) comprising a first and a second supporting side wall (7,8) for supporting the battery cells (6) in the respective battery module (4,5), the first and the second supporting side wall (7,8) of the battery modules (4,5) being opposing vertical side walls provided on a respective side of the battery cells (6) in the battery modules (4,5), the first and/or the second supporting side wall (7,8) having a respective inner side (7a,8a) facing the battery cells (6) and a respective outer side (7b,8b) facing away from the battery cells (6), the first and/or the second supporting side wall (7,8) comprising first supporting element(s) adapted to support and bear the load of the battery cells (6) in the first and second battery modules (4,5), as seen in the height direction (y), or alternatively a respective bottom support plate (15,16) is connected to the first and the second supporting side walls (7,8), the first and/or the second supporting side wall (7,8) comprises liquid cooling channels (12), the liquid cooling channels (12) being in the form of a groove (13) provided in the first and/or second supporting side wall (7,8) on an outer side thereof (7b,8b), the groove (12) being covered by a cover plate (14), arranged on the outer side (7b,8b) of the first and/or the second supporting side wall (7,8), thereby forming integrated liquid cooling system (3) for the first and the second battery module (4,5) in the first and/or second supporting side wall (7,8).