Insulating Oil Battery Module for Direct Cell Cooling
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Solution Overview
Problem
Conventional battery packs face limitations in cooling efficiency, weight, and energy density due to indirect cooling methods and complex, heavy metal-based structures, necessitating a solution that improves cooling performance, reduces weight, and enhances energy density.
Innovation Solution
A battery module design featuring a stack of battery cells, a high-rigidity module housing, and insulating oil that directly cools the cells by flowing through the housing, eliminating the need for additional cooling members and simplifying the assembly process, with electrical connections via HV connectors and a battery management system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect cooling method with heat transfer members is used, then cooling function is provided, but cooling efficiency is limited and device complexity increases
Solution Approach 1:
The patent removes the heat transfer member from the cooling system, allowing the insulating oil to directly contact and cool the battery cell. This extraction of the intermediate component simplifies the cooling system structure while improving cooling efficiency through direct thermal contact between the insulating oil and battery cell surface.
2Reliability
If multiple metal parts are used for safety and structural support, then reliability is improved, but weight increases and energy density decreases
Solution Approach 1:
The patent combines multiple structural functions into the module housing, which serves simultaneously as the protective enclosure and the structural support framework. This merging of functions eliminates the need for separate crossbeams and reinforcement parts, reducing overall weight while maintaining structural integrity and safety.
Solution Approach 2:
The module housing is designed to perform multiple functions: it provides structural support, ensures safety protection, and serves as the cooling system component through which insulating oil flows. This multi-functionality reduces the number of separate components needed, thereby reducing weight and improving energy density.
3Reliability
If multiple metal parts are used for safety protection, then reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the protective function with the module housing itself, eliminating the need for separate protective parts such as crossbeams and reinforcement structures. This simplifies the assembly process by reducing the number of components that need to be manufactured and assembled, while still providing necessary safety protection.
4Temperature
If conventional cooling members are used, then cooling function is provided, but energy density is reduced due to additional components
Solution Approach 1:
The insulating oil serves dual purposes: it provides electrical insulation and simultaneously functions as the cooling medium. This self-service approach eliminates the need for separate cooling fluids or additional cooling components, thereby improving energy density while maintaining effective cooling performance.
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 significantly enhances cooling efficiency, reduces the weight and manufacturing costs of battery packs, and improves energy density by directly cooling battery cells with insulating oil, while simplifying the manufacturing process and eliminating unnecessary reinforcement parts.
Implementation Method 1
an insulating oil configured to cool the plurality of battery cells
Implementation Method 2
the insulating oil directly cools the plurality of battery cells while flowing in the module housing
Data Source
AI summary
The present invention relates to a battery module including a battery cell stack comprising a plurality of battery cells, a module housing configured to receive at least one battery cell stack disposed in an overall length direction, a high voltage (HV) connector configured to electrically connect battery modules to each other, a low voltage (LV) assembly configured to sense the voltage and temperature of the plurality of battery cells, an insulating oil configured to cool the plurality of battery cells, and a cooling port configured to allow the insulating oil to be introduced and discharged therethrough, wherein the insulating oil directly cools the plurality of battery cells while flowing in the module housing, whereby cooling efficiency and energy density are improved, and a battery pack including the same.