Recessed Battery Case Structure for Compact Cooling Channels
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Solution Overview
Problem
Existing secondary batteries face challenges in effectively managing heat generation and cooling efficiency, particularly at the module and pack levels, which can lead to increased risk of combustion and reduced performance.
Innovation Solution
The design incorporates a secondary battery case with a recessed portion on its bottom surface, allowing for a non-recessed portion to couple with an adjacent cell, creating a cooling channel that enhances forced cooling efficiency and compact module size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a flat bottom surface is used in conventional secondary batteries, then the manufacturing process is simple, but the cooling efficiency is insufficient and heat dissipation is poor
Solution Approach 1:
The bottom surface of the case is segmented into multiple functional regions: a recessed portion that receives the cooling plate and a non-recessed portion that protrudes to couple with adjacent cells. This segmentation allows the case to simultaneously accommodate cooling components and form cooling channels with neighboring cells, thereby improving cooling efficiency without requiring a completely new case design.
Solution Approach 2:
The non-recessed portion of the bottom surface serves multiple functions: it structurally couples adjacent secondary batteries together to form modules, and simultaneously defines the boundary of the cooling channel that enables heat dissipation. This multi-functionality resolves the contradiction by making the case structure itself serve both mechanical and thermal management purposes.
2Temperature
If cooling channels are added to improve heat dissipation, then cooling efficiency increases, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The cooling channel is formed by merging the recessed portion of one cell's bottom surface with the non-recessed portion of the adjacent cell's bottom surface. This merging creates an integrated cooling structure that eliminates the need for separate cooling channel components, thereby improving heat dissipation while maintaining manufacturing simplicity.
Solution Approach 2:
The cooling plate is nested within the recessed portion of the case bottom surface, allowing the cooling component to be housed within the existing case structure rather than requiring external attachment. This nesting approach integrates thermal management into the case design without adding external complexity.
3Area of stationary object
If the bottom surface is made uniform for easy assembly, then manufacturing is simple, but the cooling area is reduced
Solution Approach 1:
The bottom surface is designed with local quality variations: the recessed portion provides a localized area for accommodating the cooling plate and forming the cooling channel, while the non-recessed portion maintains a uniform structure for coupling with adjacent cells. This local differentiation increases the effective cooling area without complicating the overall assembly process.
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 configuration improves cooling efficiency and reduces heat generation by increasing the cooling area and allowing for more effective heat dissipation, thereby enhancing safety and performance of secondary batteries.
Implementation Method 1
a cooling channel between the bottom surface of the upper rack cell and the bottom surface of the lower rack cell, which are coupled
Data Source
AI summary
A secondary battery including a case having a bottom surface, the bottom surface including a recessed portion and a non-recessed portion, the recessed portion being recessed into an interior of the case, and the non-recessed portion being flat, and an upper surface facing the bottom surfaces, the upper surfaces including a cap assembly, and an electrode assembly accommodated in the case.