Integrated Cooling Fin Battery Module Array Design
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Solution Overview
Problem
Existing battery module arrays face challenges in achieving optimal space utilization, leading to inefficient packaging and increased manufacturing costs due to complex assembly requirements and potential tolerance issues with cooling fins.
Innovation Solution
A battery module array design featuring two secondary battery cells, a rectangular module frame with integrated cooling fins, end plates, tension bars, sensing line assemblies, and covers, which allows for improved space utilization and simplified manufacturing by reducing extrusion tolerances and eliminating the need for separate bolt or nut grooves for module coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional battery module arrays are assembled with multiple secondary battery cells and cooling fins, then the battery pack can provide adequate cooling capacity, but the space utilization becomes inefficient and manufacturing complexity increases
Solution Approach 1:
The patent merges the cooling fin structure with the module frame into an integrated unit. The cooling fin is directly formed as part of the module frame structure, eliminating the need for separate cooling fin components and their associated mounting operations. This integration reduces the number of parts and assembly steps while maintaining adequate cooling capacity through optimized fin placement and geometry.
Solution Approach 2:
The module frame is designed to serve multiple functions simultaneously: it provides structural support for the battery cells, acts as a mounting platform for the cooling fin, and serves as part of the cooling system itself. This multi-functionality reduces the overall component count and simplifies the assembly process while maintaining both mechanical integrity and thermal management capabilities.
2Temperature
If traditional battery module arrays use separate cooling fins requiring extrusion processes, then cooling functionality is provided, but manufacturing precision requirements increase and costs rise
Solution Approach 1:
By integrating the cooling fin structure with the module frame, the patent eliminates the need for separate extrusion processes for cooling fins. The cooling fin becomes an integral part of the frame structure, manufactured in the same process, thereby eliminating tolerance accumulation between separate components and reducing manufacturing precision requirements.
Solution Approach 2:
The patent extracts the cooling fin from being a separate manufactured component and transforms it into an integral feature of the module frame. This extraction of the cooling fin as an independent part eliminates the need for separate extrusion tolerances and reduces manufacturing complexity while maintaining cooling functionality.
3Strength
If battery modules are designed with complex coupling requirements including bolt or nut grooves, then mechanical connection strength is ensured, but manufacturing costs and assembly time increase
Solution Approach 1:
The patent merges the coupling function into the basic module assembly process itself, eliminating the need for separate coupling features like bolt or nut grooves. The modules are designed to couple directly through their frame structures, integrating the connection function into the primary assembly operation and reducing manufacturing complexity.
Solution Approach 2:
Instead of adding complex coupling features (bolt grooves, nut slots) to ensure mechanical connection, the patent inverts the approach by designing modules that couple through their essential frame structures. The coupling capability is inherent in the basic module design rather than being an added complexity, thereby reducing manufacturing costs while maintaining connection strength.
4Device complexity
If battery module arrays use standardized two-cell modules, then space utilization is improved and manufacturing is simplified, but flexibility in configuration may be reduced
Solution Approach 1:
The standardized two-cell module is designed with universal coupling interfaces and integrated cooling that allow it to function in multiple configuration scenarios. The module's frame structure and coupling mechanism are designed to accommodate different array configurations while maintaining assembly simplicity, thereby achieving both standardization benefits and configuration flexibility.
Data Source
AI summary
Disclosed is a battery module array including battery modules, which may have improved space utilization. The battery module array includes a plurality of battery modules, each having two secondary battery cells, a module frame and a cooling fin. If the battery module array is configured using the above battery modules, space utilization may be improved.