Vehicle Battery Module With Wave-Shaped Cooling Channel

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Solution Overview

Problem

Existing battery modules for vehicles face challenges in maintaining high energy density while ensuring stable operation and efficient cooling, as they require effective heat management to prevent overheating.

Innovation Solution

A battery module design featuring overlapping battery cells with a cooling channel module directly bonded to their surfaces, utilizing a wave-shaped cross section for enhanced heat transfer and a refrigerant circulation system, along with a cover plate for additional cooling and structural rigidity, minimizing the heat transfer path and maximizing the heat transfer area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery cells are overlapped to increase energy density, then energy density is improved, but heat dissipation becomes more difficult and cooling performance deteriorates

Engineering Contradiction:

Improveenergy densityVSAvoidcooling performance

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The patent transitions from traditional lateral arrangement of battery cells to a vertical overlapping arrangement in the thickness direction. This dimensional change allows for compact energy storage while enabling direct thermal contact between stacked cells and the cooling channel module, improving heat dissipation despite increased density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The cooling channel module employs a wave-shaped cross-section that curves along the curvature formed by end portions of overlapped battery cells. This curved geometry maximizes the bonding surface area between the cooling module and battery cells, enhancing heat transfer efficiency from the compact stacked cells.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Device complexity

If a simple layout with fewer parts is used, then device complexity is reduced, but cooling performance may be insufficient

Engineering Contradiction:

Improvelayout simplicityVSAvoidcooling performance

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The patent merges the cooling channel module directly with the battery cell assembly through bonding, eliminating the need for separate cooling plates or thermal interface materials. The wave-shaped cooling channel is integrated into the structure, providing both cooling function and structural support with a single component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling channel module serves multiple functions: it provides thermal management through refrigerant circulation, acts as a structural support element, and maintains uniform spacing between overlapped battery cells. This multi-functionality reduces the need for additional dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Area of stationary object

If cooling channel module is directly bonded to battery cells, then heat transfer area is maximized, but manufacturing precision requirements increase

Engineering Contradiction:

Improveheat transfer areaVSAvoidbonding precision

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The wave-shaped cross-section of the cooling channel module is designed to match the curvature of battery cell end portions. This geometric parameter matching ensures that the bonding surfaces naturally align, reducing the tolerance requirements for bonding precision while maximizing contact area.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The cooling channel module features localized wave-shaped curvature at specific bonding regions that corresponds to the battery cell geometry. This local geometric adaptation ensures optimal contact at critical heat transfer zones without requiring high precision across the entire assembly.

Inventive Principle:

Principle #3Local quality

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 design achieves efficient heat dissipation and maximizes cooling performance while reducing the module's size and part count, ensuring stable operation and minimizing volume.

Implementation Method 1

a cooling channel module directly bonded to at least one surface parallel to an overlap direction of the battery cells of the cell module and having a refrigerant circulated therein

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a cell bonding surface of the cooling channel module has a wave-shaped cross section curved along a curvature formed by end portions of the overlapped battery cells

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

The cell module and the cooling channel module may be bonded to each other by a heat radiating adhesive

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS11652249B2Battery module for vehicle

Publication Date: 2023.05.16 HYUNDAI MOTOR CO LTD

AI summary

A battery module for a vehicle includes a cell module in which battery cells are overlapped with each other while having a predetermined directivity, and a cooling channel module directly bonded to at least one surface parallel to an overlap direction of the battery cells of the cell module, the cooling channel module having a refrigerant circulated therein, where a cell bonding surface of the cooling channel module has a wave-shaped cross section curved along a curvature formed by end portions of the overlapped battery cells.