Cell Module Cooling Channels Integrated Into Outer Walls

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Solution Overview

Problem

Existing battery cooling systems for electric and hybrid vehicles are inefficient, complex, and costly due to the need for separate thermally conductive plates and cooling pipes, which result in lost cooling performance, increased weight, and high maintenance costs.

Innovation Solution

Integration of pipe-shaped cavities for heat exchange within the outer walls of cell modules, eliminating the need for separate cooling plates and pipes by using extrusion-molded profiles to create a direct and efficient heat exchange system, with a meandering flow path for the heat exchange medium.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate thermally conductive plates and cooling pipes are used for battery cooling, then cooling function is provided, but device complexity increases and manufacturing cost increases

Engineering Contradiction:

Improvecooling functionVSAvoidconstruction complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the housing structure and cooling channels into a single integrated component. The cooling channels are formed directly within the housing walls through injection molding, eliminating the need for separate thermally conductive plates and cooling pipes. This merging of structural and cooling functions reduces device complexity while maintaining effective cooling performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing serves multiple functions simultaneously: it provides mechanical protection for the battery cells, structural support for the battery assembly, and acts as a heat exchange medium through integrated cooling channels. This multi-functionality eliminates the need for separate dedicated cooling components, simplifying the overall construction.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate thermally conductive plates and cooling pipes are used for battery cooling, then cooling function is provided, but manufacturing cost increases

Engineering Contradiction:

Improvecooling functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The housing and cooling channels are manufactured as a single integrated component using injection molding technology. This eliminates the need for separate manufacturing processes for thermally conductive plates and cooling pipes, reducing manufacturing steps, material costs, and assembly operations, thereby lowering overall manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical cooling systems (separate plates and pipes requiring assembly) with an integrated molded structure. The cooling channels are formed directly in the housing during molding, eliminating mechanical assembly steps and reducing manufacturing complexity and cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If separate thermally conductive plates and cooling pipes are used for battery cooling, then cooling function is provided, but weight increases

Engineering Contradiction:

Improvecooling functionVSAvoidbattery weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The housing and cooling channels are combined into a single component, eliminating redundant materials and structures. The integrated design removes the weight of separate thermally conductive plates and cooling pipes while maintaining the cooling function through channels formed within the housing walls.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If separate thermally conductive plates and cooling pipes are used for battery cooling, then cooling function is provided, but cooling efficiency decreases due to heat loss at housing

Engineering Contradiction:

Improvecooling functionVSAvoidcooling performance loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The cooling channels are integrated directly into the housing structure, eliminating intermediate thermal interfaces such as adhesive layers and gap fillers that exist in separate plate configurations. This direct integration reduces thermal resistance and minimizes heat loss at the housing, improving overall cooling efficiency.

Inventive Principle:

Principle #5Merging (Combining)

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 production costs and weight, simplifies construction, and minimizes maintenance by integrating the cooling system directly into the cell module housing, while also providing a crash structure to absorb impacts and improve safety.

Implementation Method 1

In the operating state, the rechargeable battery cells or individual cells are heated to an operating temperature or else cooled in order to dissipate ensuing heat loss

Methodology Applied

Scientific EffectHeat exchange: Conduction (thermal)