Battery Module Flow Path Spacer for Direct Cell Cooling
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Solution Overview
Problem
Indirect water-cooling methods in battery modules result in limited cooling performance and increased volume due to the lack of direct contact between cooling water and battery cells, leading to energy density losses.
Innovation Solution
A battery module design where an insulating cooling liquid directly contacts battery cells and electrical connection parts through a flow path spacer, allowing efficient cooling by flowing between adjacent cells and electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect water cooling is used with a cooling device outside the module housing, then the battery cell can be cooled, but the overall volume of the battery module increases and cooling performance is limited
Solution Approach 1:
The flow path spacer integrates multiple functions: it creates cooling channels between battery cells, provides structural support, and enables direct contact cooling without requiring external cooling devices. The spacer merges the cooling system with the structural framework of the battery module, eliminating the need for separate cooling chambers or external heat sinks.
Solution Approach 2:
The cooling flow paths are nested within the spaces created by the flow path spacer between adjacent battery cells. The spacer is positioned in the gaps between cells, and the cooling liquid flows through channels formed within this nested structure, maximizing space utilization without increasing overall module volume.
2Temperature
If indirect water cooling is used through module housing, then the structure is simple, but the cooling liquid does not directly contact battery cell leading to limited cooling performance
Solution Approach 1:
The flow path spacer extracts the cooling function from the external environment and places it directly between the battery cells. By positioning the spacer within the cell assembly and creating internal flow channels, the system achieves direct contact cooling without complex external piping, pumps, or heat exchangers.
Solution Approach 2:
The flow path spacer is made of insulating material that is naturally resistant to electrolyte corrosion, eliminating the need for additional protective coatings or materials. The spacer's insulating properties inherently prevent short circuits while its porous structure enables efficient heat transfer, making the system self-sufficient without additional protective mechanisms.
3Temperature
If cooling liquid is introduced directly into module housing to contact battery cell, then cooling performance improves, but the cooling liquid must flow smoothly through complex paths between cells
Solution Approach 1:
The flow path spacer divides the cooling system into multiple segmented channels between adjacent battery cells. Each spacer creates independent flow paths on either side, allowing cooling liquid to efficiently reach multiple cells simultaneously through a modular, repeating pattern that simplifies the overall flow distribution.
Solution Approach 2:
The flow path spacer is positioned locally between specific adjacent battery cells to create targeted cooling zones. The insulating material properties and flow channel dimensions are optimized for local heat dissipation requirements, allowing different regions of the battery module to be cooled according to their specific thermal loads.
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 enables rapid and efficient cooling of battery cells and electrical components, improving cooling performance and energy density by allowing the insulating cooling liquid to flow smoothly and directly contact the cells and connection parts.
Implementation Method 1
an insulating cooling liquid flowing into a module housing to cool a battery cell directly contacts parts such as an electrode lead, a bus bar, etc. of the battery cell to cause efficient cooling
Data Source
AI summary
A battery module includes a sub module including a cell stack assembly having a plurality of battery cells and a flow path spacer interposed between adjacent battery cells and having a cooling liquid flow path for allowing an insulating cooling liquid to flow in direct contact with the battery cells; a module housing configured to accommodate the sub module; a front sealing plate configured to cover an opening at one longitudinal side of the module housing and having an inlet for introducing the insulating cooling liquid; and a rear sealing plate configured to cover an opening at the other longitudinal side of the module housing and having an outlet for discharging the insulating cooling liquid.