Modular Battery Structure With Compressible Bead Cooling
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Solution Overview
Problem
Existing battery technologies face challenges in achieving high energy density while minimizing weight and size, particularly in electric vehicles where specialized battery packs with unique form and power demands are required, leading to complex and costly design processes.
Innovation Solution
The development of an energy-dense modular battery module structure that includes an array of battery cells organized with parallel top and bottom surfaces, surrounded by a non-conductive shell, and equipped with thermally conductive compressible beads and cooling plates for efficient heat management, allowing for modular configuration and easy integration into various electric vehicle applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in a compact array with parallel top and bottom surfaces, then energy density is improved, but thermal management complexity increases
Solution Approach 1:
The battery module is segmented into individual cells arranged in a structured array, with each cell having parallel top and bottom surfaces. This segmentation allows for systematic thermal management where cooling plates can be applied uniformly across multiple cells, reducing overall thermal management complexity while maintaining high energy density
Solution Approach 2:
Thermally conductive compressible beads are introduced as an intermediary material between the cooling plates and battery cell surfaces. These beads facilitate efficient heat transfer from the cells to the cooling plates while accommodating surface irregularities, thereby simplifying thermal management in the compact battery array configuration
2Temperature
If thermally conductive compressible beads are used between cooling plates and battery cells, then heat dissipation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The compressible beads undergo a parameter change in their physical state during assembly - they are inserted in a loose, uncompressed state and then compressed by the cooling plates to achieve optimal thermal contact. This parameter change allows for simple manufacturing processes while achieving high heat dissipation efficiency
Solution Approach 2:
The compressible beads perform self-adjustment during compression, automatically conforming to the surfaces of the battery cells and cooling plates. This self-service capability eliminates the need for precise manufacturing tolerances or complex alignment procedures, reducing manufacturing complexity while maintaining effective thermal contact
3Reliability
If cooling plates with fluid channels are added to the battery module, then thermal management capability is improved, but device complexity increases
Solution Approach 1:
The cooling plates serve multiple functions: they provide thermal management through fluid channels, apply compression force to the compressible beads and battery cells, and act as structural components of the battery module. This multi-functionality reduces the need for separate components, thereby improving thermal management capability without proportionally increasing device complexity
Solution Approach 2:
The cooling system is merged with the structural framework of the battery module. The cooling plates are integrated into the module assembly, combining thermal management functions with the mechanical support structure, which reduces overall device complexity while enhancing thermal management capability
4Adaptability or versatility
If modular battery structure is implemented with standardized interfaces, then adaptability to different EV applications is improved, but manufacturing precision requirements increase
Solution Approach 1:
The battery system is segmented into standardized modules that can be independently manufactured and then assembled in various configurations for different EV applications. The segmentation with standardized interfaces allows for high adaptability while maintaining consistent, achievable manufacturing precision for each individual module
Solution Approach 2:
The modular design allows for parameter changes in the number of cells per module and the arrangement configuration, while maintaining standardized interface dimensions and tolerances. This approach enables adaptability to different applications without requiring changes to the fundamental manufacturing precision requirements of the standardized 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
The modular battery module achieves energy densities of over 400 watt-hours per liter at the module level and 350 watt-hours per liter at the pack level, with efficient thermal management and modular design enabling flexible configuration and cost-effective maintenance, thereby enhancing the performance and efficiency of electric vehicles.
Implementation Method 1
thermally conductive, compressible material may be used, e.g., thermally conductive beads may be aligned with the top and bottom surfaces of the cells
Implementation Method 2
These plates, equipped with interior fluid channels for heat dissipation
Data Source
AI summary
A battery module includes a set of battery cells organized in an array where the top and bottom surfaces are aligned in parallel planes. These cells are surrounded by a non-conductive shell. Both the top and bottom surfaces of the cells have a corresponding non-conductive layer, each with openings over the surfaces of the cells. Electrical connections to these surfaces are established through leads that pass through these openings. To manage heat, thermally conductive, compressible beads are positioned above and below the cells, making contact through the openings in the non-conductive layers. Above and below these beads are thermally conductive plates, each containing internal fluid channels for efficient heat dissipation. These plates not only facilitate cooling but also compress the beads against the battery cells, ensuring effective thermal management.