Interconnection-less Liquid Fin Battery Cooling Module
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Solution Overview
Problem
Current battery internal heat exchangers require numerous components and complex manufacturing processes due to multiple seals and intricate assembly, which complicates the cooling process and increases costs.
Innovation Solution
A battery module design featuring cooling fins with angled inlet and outlet sections and integrated cooling channels, allowing for simplified assembly and reduced component count, with coolant interfaces located outside the module to minimize seals and potential leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cooling fins with integrated inlet and outlet headers are used, then cooling function is achieved, but device complexity increases due to multiple seals and components
Solution Approach 1:
The patent extracts the inlet and outlet headers from the internal structure of the cooling fins and relocates them to external positions. This allows the cooling channels to be simple through-fins without integrated headers, reducing the number of seals and components while maintaining the cooling function. The headers are separated as independent external components rather than being integrated into the fin structure.
2Reliability
If multiple seals are used for inlet and outlet connections, then sealing reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent removes the complex integrated header structure that requires multiple seals from the cooling fin assembly. By extracting the header function to external components and using simple through-fins with cooling channels, the number of seals is dramatically reduced from multiple seals per fin to minimal seals only at the external manifold connections, significantly simplifying manufacturing while maintaining sealing reliability.
3Temperature
If cooling channels are integrated within the fins, then heat transfer efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent extracts the complex header formation and channel integration processes from the fin manufacturing. The cooling channels are simplified to straight through-fins that require minimal precision, while the header functions are moved to external manifolds. This separation reduces the manufacturing precision requirements for the fins themselves while maintaining effective heat transfer through the simplified channel geometry.
4Reliability
If numerous components are used for battery cooling, then cooling performance is achieved, but assembly complexity increases
Solution Approach 1:
The patent merges the cooling fin and cooling channel functions into a single simplified through-fin component. The inlet and outlet headers are merged into external manifolds rather than being separate integrated components. This consolidation reduces the total number of components and simplifies the assembly process while maintaining effective cooling performance through the streamlined design.
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 enhances cooling efficiency, reduces material and manufacturing costs, improves reliability, and simplifies the manufacturing process while maintaining effective heat transfer, resulting in a more robust and cost-effective battery thermal system.
Implementation Method 1
Heat from the battery cells 15 is conducted into the cooling fins 20
Implementation Method 2
circulating cooling fluid through the at least one cooling channel
Data Source
AI summary
A battery module is described. The battery module includes a plurality of cooling fins having an inlet section, a center section, and an outlet section, the inlet and outlet sections extending from opposite ends of the center section at an angle from a plane defined by the center section, the cooling fins having at least one cooling channel extending from an inlet of the inlet section through the center section to an outlet of the outlet section; and a plurality of battery cells positioned in the center section between the plurality of cooling fins. A method of cooling a battery module is also described.