Integrated Cooling Housing for Compact Battery Module Assembly
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Solution Overview
Problem
Conventional battery modules require separate fixing and cooling components, increasing volume, complexity, and manufacturing costs, while also facing challenges in space utilization, energy density, and cooling efficiency.
Innovation Solution
A battery module design featuring a cooling housing formed as a single piece with protrusions and recesses to maximize space utilization, energy density, and cooling efficiency, and a manufacturing method that minimizes the use of fixing/heat transfer resin and facilitates easy assembly of bus bar assemblies and sensing modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate fixing members and cooling members are used to stack and fix battery cells, then the battery module can be assembled, but the volume of the battery module is increased
Solution Approach 1:
The cooling housing integrates multiple functions: it serves as the cooling member with cooling plates, the fixing member with side plates and cover parts, and the protective enclosure. This merging of functions eliminates the need for separate fixing members and cooling members, thereby reducing the overall volume of the battery module while maintaining assembly capability
Solution Approach 2:
The cooling housing is designed as a multi-functional component that simultaneously provides cooling (through cooling plates), structural support and fixation (through side plates and cover parts), and protection for battery cells. This universal design reduces the number of components needed, decreasing the battery module volume
2Ease of manufacture
If separate fixing members and cooling members are used, then the battery module can be assembled, but the manufacturing process becomes complicated and time and costs are increased
Solution Approach 1:
By combining multiple functions into the cooling housing, the number of components is reduced, which simplifies the manufacturing process. Instead of manufacturing separate fixing members, cooling members, and housing components, the cooling housing is produced as an integrated structure, reducing manufacturing complexity and costs
Solution Approach 2:
The cooling housing is designed with segmented structures (cooling plates, side plates, cover parts) that can be manufactured separately and then assembled through coupling. This segmentation allows for simplified manufacturing of individual components while maintaining the integrated functionality, reducing overall manufacturing complexity
3Temperature
If cooling members are mounted on battery cells, then cooling efficiency is improved, but the volume of the battery module is increased
Solution Approach 1:
The cooling function is merged into the housing structure itself. The cooling plates are integrated with the side plates and cover parts to form the cooling housing, eliminating the need for separate cooling members mounted on battery cells. This integration maintains cooling efficiency while reducing the overall volume of the battery module
Solution Approach 2:
The cooling housing serves as both the structural enclosure and the cooling system. The cooling plates within the housing provide cooling functionality without requiring additional external cooling members, thereby maintaining cooling efficiency while minimizing volume increase
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 enhances space utilization, energy density, and cooling efficiency, reduces manufacturing time and costs, and improves the assembly process by maximizing contact areas between battery cells and the cooling housing.
Implementation Method 1
a heat transfer member, and a cooling plate... a fixing/heat transfer resin is thinly spread between a battery group and a cooling housing to increase a contact area therebetween, and thus maximize heat transfer efficiency
Implementation Method 2
a surface contact between a battery group and a cooling housing is maximized by an elastic pad provided on an upper side of the battery group
Data Source
AI summary
The present invention provides a battery module, which includes: a battery group formed by stacking a plurality of battery cells, each of which includes electrode tabs; a cooling housing including a cooling plate located corresponding to one side of sides of the battery group, in which the electrode tabs are not extended, and side plates located on both sides of the battery group perpendicular to the one side of the sides, thus to house the battery group; a cover plate located on the other side of the battery group; and a front cover part and a rear cover part, which are located at outermost front and rear of the battery group on both sides in a direction in which the electrode tabs are extended.