Battery Module Insulation Coolant Channels for Leak-Tight Cooling
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Solution Overview
Problem
Existing battery modules using indirect water cooling methods face limitations in cooling performance due to indirect contact with battery cells and require additional space for cooling devices, leading to reduced energy density and leakage risks through perforated sealing plates.
Innovation Solution
A battery module design with an insulation cooling liquid that directly contacts battery cells and electrical components, featuring a channel spacer for efficient cooling liquid flow and a sealing structure with O-rings to prevent leakage, including a front and rear sealing plate with inlets and outlets for smooth liquid circulation and secure containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect water cooling method is used, then cooling device can be provided outside module housing, but cooling performance is limited and overall volume is increased
Solution Approach 1:
The patent merges the cooling function directly into the module housing by forming cooling channels within the housing structure itself, eliminating the need for separate external cooling devices. This integration allows cooling liquid to directly contact battery cells while maintaining a compact overall volume.
Solution Approach 2:
The patent transitions from external cooling (outside the housing) to internal cooling (within the housing structure) by creating three-dimensional cooling channels embedded in the housing, enabling direct thermal contact with battery cells without increasing external dimensions.
2Temperature
If cooling liquid flows directly into module housing to cool battery cells, then rapid cooling is achieved, but risk of leakage through perforated sealing plate increases
Solution Approach 1:
The patent introduces a sealing member as an intermediary component between the cooling liquid flow path and the perforated sealing plate. This sealing member prevents direct contact between the cooling liquid and the perforated areas, eliminating leakage risk while maintaining efficient direct cooling.
Solution Approach 2:
The patent implements preventive sealing measures before leakage can occur by positioning sealing members at critical interfaces where cooling liquid might escape through perforations, thereby cushioning against potential leakage issues.
3Ease of operation
If external terminals are exposed outside sealing plate for electrical connection, then electrical connection is enabled, but cooling liquid may leak through perforated portion
Solution Approach 1:
The patent uses sealing members as intermediaries that allow electrical terminals to pass through the sealing plate while preventing cooling liquid from leaking through the same perforated areas. The sealing members create selective permeability - allowing electrical conduction while blocking liquid flow.
4Productivity
If channel structure is provided for efficient cooling, then cooling liquid flow is improved, but sealing complexity increases to prevent leakage
Solution Approach 1:
The patent designs sealing members that perform multiple functions simultaneously: sealing the interface between housing and end plates, preventing cooling liquid leakage through perforated areas, and maintaining electrical insulation. This multi-functionality reduces the need for separate sealing components.
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
Enables efficient and rapid cooling of battery cells and electrical components while preventing leakage, enhancing energy density and maintaining airtightness, especially around high-potential external terminals.
Implementation Method 1
an insulation cooling liquid introduced into a module housing to cool battery cells comes into direct contact with components such as electrode leads and bus bars of the battery cells to realize efficient cooling
Data Source
AI summary
A battery module comprises a sub module; a module housing configured to accommodate the sub module; a front sealing plate configured to cover a front opening of the module housing; and a rear sealing plate configured to cover a rear opening of the module housing. The sub module includes a cell stack assembly, a front bus bar frame assembly coupled to a front end of the cell stack assembly adjacent to the front opening of the module housing, and a rear bus bar frame assembly coupled to a rear end of the cell stack assembly adjacent to the rear opening of the module housing. The sub module includes a plurality of battery cells and a channel spacer interposed between adjacent battery cells. The front sealing plate has an inlet for introducing an insulation cooling liquid, and the rear sealing plate has an outlet for discharging the insulation cooling liquid.