Open-Frame Battery Module Cooling With Spaced Thermal Resin Layers
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Solution Overview
Problem
Conventional battery modules face challenges in effectively dissipating heat due to complex heat transfer paths and air gaps, leading to potential overheating, performance degradation, and increased risk of explosion or ignition, especially in large-sized modules exposed to high-temperature conditions.
Innovation Solution
A battery module design featuring a simplified heat transfer path with upper and lower thermal conductive resin layers spaced apart to accommodate electrode leads, a module frame with open parts, and a pack frame with a lower thermal conductive resin layer, enhancing heat dissipation and minimizing temperature deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to form a battery module, then capacity and output are improved, but heat dissipation becomes more difficult and temperature rises more quickly
Solution Approach 1:
The battery module is divided into multiple battery cell stacks arranged in parallel, with cooling channels positioned between the stacks. This segmentation allows heat to be dissipated from multiple locations simultaneously, improving overall heat dissipation efficiency while maintaining high capacity and output.
Solution Approach 2:
A cooling plate with cooling channels is introduced as an intermediary component between the battery cells and the external environment. The cooling plate provides a dedicated heat transfer path that efficiently conducts heat away from the battery cells, resolving the heat dissipation difficulty caused by stacking numerous cells.
2Temperature
If conventional cooling structures with multiple components are used, then cooling function is provided, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The cooling plate integrates multiple functions into a single component: it serves as both a structural support element and a heat dissipation device with embedded cooling channels. This merging eliminates the need for separate cooling components, reducing device complexity and manufacturing cost while maintaining effective cooling performance.
Solution Approach 2:
The cooling plate performs multiple functions simultaneously: it provides mechanical support for the battery cells, serves as a heat transfer medium, and acts as a structural framework for the module. This multi-functionality reduces the total number of components needed, simplifying the overall device structure.
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 improves cooling performance, reduces costs, increases space utilization, and extends the lifespan of the battery module and pack by effectively dissipating heat and minimizing temperature variations among cells.
Implementation Method 1
an upper thermal conductive resin layer located between the upper surface of the battery cell stack and the module frame
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked; a module frame that wraps the battery cell stack and has an open part formed on the lower side; and an upper thermal conductive resin layer located between the upper surface of the battery cell stack and the module frame. The battery cell stack is exposed in the downward direction through the open part.