Energy Storage Module Cooling Plate Retaining Element Design
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Solution Overview
Problem
Existing energy storage systems for electric and hybrid vehicles require complex assemblies with many parts, which can compromise cooling efficiency and swelling prevention, leading to inefficiencies in both assembly and space usage.
Innovation Solution
An energy storage module design featuring a cooling plate unit stacked with energy storage cell units, secured by elongated retaining elements with deformed end portions that maintain thermal contact and pre-tension, reducing the number of parts needed for assembly and cooling efficiency, and allowing for easier access and assembly of multiple modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple retaining elements and mounting structures are used to secure battery cells and cooling systems, then the mechanical stability and swelling prevention are improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the cooling plate and mounting structure into a single integrated component. The cooling plate serves dual functions: thermal management through direct thermal contact with battery cells and mechanical retention through integrated mounting features. This eliminates the need for separate retaining elements and mounting structures, reducing assembly complexity while maintaining swelling prevention capabilities.
Solution Approach 2:
The cooling plate is designed as a multi-functional component that simultaneously provides thermal conduction, mechanical support, and retention functions. By integrating multiple functions into a single component, the patent reduces the total number of parts and simplifies the assembly process while ensuring reliable battery cell securing and swelling prevention.
2Volume of moving object
If battery cells are closely packed to reduce battery size, then the volume efficiency is improved, but the thermal management efficiency deteriorates due to reduced cooling access
Solution Approach 1:
The cooling plate is integrated directly with the battery cell assembly, with the cooling surface in direct thermal contact with the battery cells. This integration ensures efficient heat transfer even when cells are closely packed, as the cooling plate follows the contour of the battery cells and maintains optimal thermal contact without requiring additional spacing.
Solution Approach 2:
The cooling plate is designed with varying thickness and thermal conductivity properties at different locations to optimize heat transfer. The plate makes direct thermal contact with high-heat-generation areas of the battery cells while maintaining structural integrity, enabling effective thermal management in compact configurations.
3Strength
If separate mounting structures are used for battery cells and cooling systems, then the mechanical stability is improved, but the thermal contact efficiency deteriorates due to additional interfaces
Solution Approach 1:
The cooling plate and mounting structure are merged into a single integrated component, eliminating the thermal interface that would exist between separate mounting structures and cooling systems. This integration ensures continuous thermal contact with battery cells while providing adequate mechanical support and stability through the integrated mounting features.
4Reliability
If multiple parts are used for assembly of battery modules, then the mechanical stability and swelling prevention are improved, but the manufacturing efficiency and assembly speed deteriorate
Solution Approach 1:
The cooling plate is designed as an integrated component that combines thermal management and mechanical retention functions. This integration reduces the number of parts that need to be assembled and the number of assembly steps required, thereby increasing manufacturing efficiency and assembly speed while maintaining reliable battery cell securing and swelling prevention.
5Strength
If complex mounting structures are used to secure multiple modules, then the mechanical stability is improved, but the ease of assembly and maintenance deteriorates
Solution Approach 1:
The cooling plate integrates mounting features directly into the thermal management component, simplifying the assembly process. Modules can be secured by simply mounting the cooling plate, which simultaneously provides thermal contact and mechanical retention. This integration maintains mechanical stability while significantly improving ease of assembly and maintenance compared to complex separate mounting 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 design simplifies assembly, enhances thermal contact, and reduces part count, resulting in a more efficient and space-saving energy storage system that effectively manages heat and prevents swelling, while maintaining performance.
Implementation Method 1
a cooling plate unit (202) stacked with the energy storage cell unit (204) in a longitudinal direction (206), the cooling plate unit (202) being in thermal contact with the energy storage cell unit (204)
Data Source
Figure 1~2a
Figure 2b
Figure 3
AI summary
The present invention relates to an energy storage module (200), an energy storage system (300) comprising such modules and to a method for manufacturing an energy storage system. The energy storage module comprises an energy storage cell unit (204) and a cooling plate unit (202) which are kept in thermal contact with each other by a first retaining element (210) having a through-hole (212) and two deformed end portions (214, 216). One of the end portions are deformed after the first retaining element has been arranged through the energy storage cell unit and the cooling plate unit. Two or more modules may be stacked together to form an energy storage system. The modules are then held together by a second retaining element (302) arranged through the through-hole of the first retaining element.