Battery Module Housing With Integrated Cooling and Frame Elimination
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Solution Overview
Problem
Existing battery modules require complex manufacturing processes, increased component consumption, and weight due to the need for additional framing to meet high power demands, which complicates the assembly and increases costs.
Innovation Solution
A battery module design that includes a series of cell stacks with insulation members, a module housing with integrated receiving parts and cooling channels, and a simplified coupling mechanism, eliminating the need for external frames and allowing for efficient assembly and cooling of multiple cell stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If additional framing is added to meet high power demands, then power output is improved, but device complexity and weight increase
Solution Approach 1:
The module housing integrates multiple functions: it provides structural support, contains receiving parts for cell stacks, and incorporates cooling channels. This merging of structural and cooling functions into a single integrated component reduces the number of separate framing elements needed, thereby reducing manufacturing complexity while maintaining high power output capability
Solution Approach 2:
The module housing serves multiple purposes simultaneously: it acts as the outer structural frame, provides receiving parts for accommodating cell stacks, and contains integrated cooling channels. This multi-functionality eliminates the need for separate framing components, reducing both device complexity and weight while supporting high power demands
2Power
If additional framing is added to meet high power demands, then power output is improved, but weight increases
Solution Approach 1:
The module housing combines structural support and cooling functions into one component, eliminating the need for separate framing elements. This reduction in component count directly reduces the overall weight of the battery module while maintaining the structural integrity needed for high power applications
Solution Approach 2:
The module housing performs multiple functions (structural support, cell stack accommodation, and cooling) simultaneously, reducing the total material required compared to traditional designs with separate framing and cooling components, thereby reducing weight
3Temperature
If traditional separate cooling and framing components are used, then cooling function is provided, but manufacturing process becomes complex
Solution Approach 1:
The cooling channels are integrated directly into the module housing structure, eliminating the need for separate cooling components and their associated assembly steps. This integration maintains effective cooling while significantly simplifying the manufacturing process and reducing assembly complexity
Solution Approach 2:
The module housing simultaneously provides structural support and integrated cooling channels, reducing the total number of components that need to be manufactured and assembled. This multi-functionality directly improves ease of manufacture while maintaining cooling efficiency
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 simplifies manufacturing, reduces weight, and enhances power output while effectively cooling and protecting the cell stacks, improving efficiency and safety through integrated cooling channels and modular coupling.
Implementation Method 1
a cooling channel for a coolant to flow to cool the series of receiving parts and the series of cell stacks
Data Source
AI summary
A battery module includes a module including a series of cell stacks, each having a series of unit cells arranged in a first direction, and an insulation member insulating at least one unit cell. The battery module also includes a module housing and a series of receiving parts in the module housing accommodating the cell stacks. Each receiving part includes a fixed wall around a respective cell stack and having a portion in contact with the cell stack. The fixed wall includes a pair of end walls at opposite ends of the receiving part in the first direction. The pair of end walls are configured to engage respective end surfaces of the corresponding cell stack in the first direction. The battery module also includes a cooling channel below a floor surface of the module housing for a coolant to flow to cool the receiving parts and the cells stacks.