Frameless Battery Module Structure for Better Heat Dissipation
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Solution Overview
Problem
Existing battery modules and packs face challenges in effectively dissipating heat generated by multiple cells, leading to accelerated degradation, increased risk of explosion or ignition, and reduced lifespan due to inadequate cooling systems, especially in high-temperature environments.
Innovation Solution
A battery module design featuring a battery cell stack covered by first and second sensing blocks with an elastic member, exposing the lower side for direct heat dissipation, and incorporating a thermally conductive resin layer for improved heat transfer, along with a module-less structure that eliminates the need for a frame, enhancing cooling performance and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery cells are stacked to increase capacity and output, then the battery module achieves higher energy density and power, but heat dissipation becomes more difficult and temperature increases
Solution Approach 1:
The patent introduces cooling fins that extend in the vertical dimension between stacked battery cells, creating a three-dimensional heat dissipation structure. This allows heat to be dissipated not only horizontally but also vertically through the extended surface area of the fins, effectively addressing the heat accumulation problem in multi-cell configurations
Solution Approach 2:
The cooling fins act as intermediary thermal conduction elements between the battery cells and the heat dissipation path. The fins are thermally coupled to the battery cells and provide a dedicated heat transfer medium that conducts heat away from the cells, facilitating efficient thermal management in the multi-cell stack
2Strength
If a traditional battery module frame structure is used, then structural support is provided, but heat transfer paths are complicated and cooling performance deteriorates
Solution Approach 1:
The patent extracts the frame structure from the traditional battery module design, transitioning to a frameless configuration. This removal of the frame eliminates the thermal barrier that the frame created between battery cells and the cooling system, enabling direct and simplified heat transfer paths while maintaining structural integrity through alternative means
Solution Approach 2:
The battery case is designed to serve multiple functions: it provides structural support, acts as a mounting surface for cooling fins, and serves as a thermal conduction path. This multi-functionality eliminates the need for a separate frame structure while maintaining both mechanical strength and thermal management effectiveness
3Quantity of substance
If battery cells are tightly packed to increase energy density, then space utilization improves, but heat accumulation accelerates and lifespan decreases
Solution Approach 1:
The cooling fins serve as intermediary thermal management components positioned between tightly packed battery cells. These fins provide dedicated heat conduction pathways that allow efficient heat removal even when cells are closely arranged, preventing heat accumulation that would otherwise accelerate degradation and reduce lifespan
Solution Approach 2:
The patent implements localized cooling by positioning cooling fins at specific high-heat-generation areas between battery cells. This targeted approach to thermal management addresses heat accumulation at critical locations without requiring increased spacing between cells, thereby maintaining high energy density while extending battery lifespan through effective local heat dissipation
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 heat transfer paths, suppresses cell swelling, and improves cooling performance while ensuring structural integrity and safety, reducing the risk of degradation and explosion, and enhancing the battery's lifespan.
Implementation Method 1
a thermally conductive resin layer positioned between the battery module and a bottom portion of the pack frame
Implementation Method 2
an elastic member configured to cover the first sensing block, the second sensing block, and two opposite lateral sides of the battery cell stack
Data Source
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AI summary
An exemplary embodiment of the present invention provides a battery module including: a battery cell stack made by stacking a plurality of battery cells including electrode leads; first and second sensing blocks configured to respectively cover front and rear sides of the battery cell stack from which the electrode leads protrude; and an elastic member configured to cover the first sensing block, the second sensing block, and two opposite lateral sides of the battery cell stack.