Battery Module Frame and Cooling Layout for Swelling Cells
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Solution Overview
Problem
Conventional battery modules with water-cooled type cooling structures face challenges in effectively managing heat dissipation, particularly when using battery cells with high swelling characteristics, leading to potential structural damage and increased risk of cracking due to uneven stress distribution.
Innovation Solution
A battery module design featuring a moving cooling structure and frame configuration that accommodates swelling battery cells, utilizing disc springs and leaf spring side plates to absorb expansion, combined with a zigzag-shaped heat sink for surface cooling, which allows for fluid movement and reduced stress on the battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a water-cooled type cooling structure is used to improve cooling performance, then heat dissipation efficiency is improved, but stress concentration and cracking risk increase due to rigid frame constraints on swelling cells
Solution Approach 1:
The frame structure is designed with movable connections that allow dynamic adjustment to accommodate battery cell swelling during charging cycles. The side plates and end plates are connected through movable joints that can expand and contract, maintaining structural integrity while allowing the cooling structure to adapt to cell volume changes without causing stress concentration or cracking.
Solution Approach 2:
The cooling structure incorporates flexible elements such as elastic bands or flexible connectors between the rigid cooling plates and the battery cells. These flexible components act as buffers that absorb swelling forces while maintaining thermal contact, allowing the rigid water-cooled structure to remain effective without transferring harmful stresses to the battery cells.
2Strength
If a rigid frame structure is used to maintain structural stability, then mechanical strength is improved, but swelling accommodation and stress distribution deteriorate
Solution Approach 1:
The frame structure is designed with movable connections that allow dynamic adjustment to accommodate battery cell swelling during charging cycles. The side plates and end plates are connected through movable joints that can expand and contract, maintaining structural integrity while allowing the cooling structure to adapt to cell volume changes without causing stress concentration or cracking.
Solution Approach 2:
The frame structure incorporates cushioning elements such as elastic bands, rubber buffers, or spring mechanisms at critical connection points before swelling forces are generated. These pre-installed cushioning elements absorb and distribute swelling forces, preventing stress concentration on the battery cells while maintaining overall frame strength and structural stability.
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 minimizes structural damage during swelling by providing a flexible cooling and frame structure, enhancing cooling performance and preventing cracks in battery cells, thus extending the lifespan and safety of the battery module.
Implementation Method 1
a disc spring part (700) located on an outside of a side plate (600) of the side plates, wherein the disc spring part (700) is compressed in a direction parallel to the first direction (d1)
Implementation Method 2
a cooling tube (310) continuing in a zigzag shape among the battery cells (110), wherein the cooling tube (310) includes bent parts (310B) in a bent form
Implementation Method 3
the cooling tube (310) includes bent parts (310B) in a bent form, wherein any one of the bent parts (310B) surrounds opposite side surfaces of any one of the battery cell groups (110G) and the first cell frame (210), and another one of the bent parts (310B) surrounds the opposite side surfaces of another of the battery cell groups (110G) and the second cell frame (220)
Data Source
AI summary
Discussed is a battery module that may include a battery cell stack including a plurality of battery cells arranged along a first direction; side plates covering each of opposite side surfaces of the battery cell stack along the first direction, respectively; a busbar frame covering one surface of the battery cell stack in a direction in which electrode leads of the plurality of battery cells protrude; and a disc spring part located on an outside of a side plate of the side plates. The disc spring part is compressed in a direction parallel to the first direction.