Battery Cell Stack Cooling Structure With Direct Coolant Flow
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Solution Overview
Problem
Conventional battery modules suffer from poor cooling efficiency due to air gaps and edge cooling systems, leading to accelerated deterioration and increased risk of ignition, especially in high-temperature environments, and are unsuitable for transportation due to weight and energy density limitations.
Innovation Solution
A battery assembly with a frame structure that houses a battery cell stack, featuring pad members extending from the ceiling to the bottom, separated coolant flow paths, and direct coolant contact with the cells, along with cooling fins and end plates to enhance cooling efficiency and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional heat sink with air gaps is used for cooling, then the structure is simple, but the cooling efficiency is poor due to obstructed heat transfer
Solution Approach 1:
The patent removes the conventional heat sink component entirely and extracts the cooling function by allowing coolant to flow directly into the battery module's internal space, eliminating the air gaps and thermal resistance layers that existed in the conventional heat sink structure
Solution Approach 2:
The cooling function is merged with the battery module structure itself by integrating coolant flow paths directly within the module, combining the structural housing and cooling system into a unified design rather than using separate cooling components
2Temperature
If edge cooling system is used, then the structure is simple, but the cooling efficiency is poor due to heat discharge through narrow lower edge portion only
Solution Approach 1:
The patent transitions from one-dimensional edge cooling (only through the lower edge) to three-dimensional volumetric cooling by allowing coolant to flow through the entire internal volume of the battery module, contacting battery cells from multiple directions and positions simultaneously
3Quantity of substance
If a plurality of battery modules are concentratedly disposed to increase mileage, then the energy density increases, but the flame or heat generated in one battery module can easily propagate to adjacent battery modules
Solution Approach 1:
The patent introduces coolant as an intermediary substance that flows through the battery module, absorbing and removing heat generated during operation, thereby preventing heat accumulation and reducing the risk of thermal propagation to adjacent modules
Solution Approach 2:
The battery module's own structure is designed to provide cooling through internal coolant flow paths, allowing the module to self-regulate its temperature without requiring external cooling systems, thus improving safety while maintaining compact design
4Quantity of substance
If conventional battery pack structure is used, then the battery module can be housed, but the weight is heavy and unsuitable for loading into means of transportation
Solution Approach 1:
The patent merges the battery module housing and cooling system into a single integrated structure, eliminating the need for separate cooling components and reducing overall weight while maintaining protective housing functions
Solution Approach 2:
The patent changes the cooling approach from solid-contact heat sinks to fluid-based direct coolant cooling, which allows for more efficient heat removal with lighter materials and reduced thermal mass, thereby decreasing overall weight
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 direct coolant contact and optimized flow paths improve cooling efficiency, reduce stagnation, and prevent performance degradation, extending battery life and safety, while allowing for better energy density and transportability.
Implementation Method 1
the coolant contacts the battery cells housed inside the frame directly to cool the battery cells
Implementation Method 2
an inlet and an outlet for circulating a coolant inside the frame, wherein the coolant is flowed into the inside of the frame through the inlet, and discharged through the outlet
Data Source
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AI summary
A battery assembly according to certain embodiments of the present disclosure includes: a battery cell stack in which a plurality of battery cells are stacked; a frame that houses the battery cell stack and includes a first side surface part, a second side surface part, a ceiling part, and a bottom part; and an inlet and an outlet for circulating a coolant inside the frame. The coolant is flowed into the inside of the frame through the inlet, and discharged through the outlet. Pad members are disposed on at least at one place between the battery cells, and at least one of the pad members extends from the ceiling part to the bottom part of the frame.