Roll-Bonded Battery Module Frame for Uniform Cell Cooling
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Solution Overview
Problem
Existing battery modules face challenges with increased manufacturing costs, complex assembly processes, and inefficient cooling due to inflexible cooling channel designs, leading to overheating, reduced performance, and shortened lifespan, especially in high-capacity battery systems.
Innovation Solution
A battery module design featuring a frame with roll-bonded metal sheets that form a C-shaped structure with integrated cooling channels, allowing for flexible cooling channel designs and improved thermal propagation by inflating top flap portions to press against battery cells and vent covers, ensuring uniform cooling and reduced assembly effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional rigid cooling channel designs are used in battery modules, then manufacturing is simpler, but cooling efficiency is insufficient leading to overheating
Solution Approach 1:
The cooling channel is designed with an inflatable section that can transition from a compressed state during assembly to an inflated state during operation. This dynamic transformation allows the cooling channel to adapt its shape and size, improving contact with battery cells and enhancing cooling efficiency while maintaining manufacturing simplicity.
Solution Approach 2:
The cooling channel's physical parameters (volume, shape, position) are changed through inflation. The inflatable section can be expanded to adjust the cooling channel's cross-sectional area and orientation, allowing optimization of cooling performance based on thermal requirements without complicating the overall structure.
2Temperature
If complex assembly processes are used to achieve precise cooling channel positioning, then cooling efficiency improves, but manufacturing cost and time increase
Solution Approach 1:
The inflatable cooling channel performs self-positioning and self-adjustment during the inflation process. As the cooling channel inflates, it naturally conforms to the battery cell surfaces and optimizes its position for maximum thermal contact, eliminating the need for complex pre-positioning mechanisms or precision assembly procedures.
Solution Approach 2:
The cooling channel is pre-formed in a compressed state that facilitates easy insertion and assembly. After assembly is complete, the inflation action transforms it into the operational cooling configuration, separating the assembly simplicity from the operational effectiveness.
3Productivity
If inflexible cooling channel designs are used, then manufacturing is easier, but cooling performance deteriorates under varying thermal loads
Solution Approach 1:
The cooling channel incorporates an inflatable section that can dynamically adjust its geometry in response to varying thermal loads. When higher cooling performance is needed, the channel can be inflated to increase its contact area with battery cells, providing adaptive cooling without requiring multiple fixed configurations.
4Productivity
If traditional battery module assembly methods are used, then structural integrity is maintained, but assembly time and cost increase
Solution Approach 1:
The cooling channel is integrated directly into the battery module structure as a unified component rather than a separate assembly. The inflatable cooling channel forms part of the module's structural framework, combining cooling functionality with structural support to reduce assembly steps while maintaining integrity.
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 achieves cost-effective, efficient cooling with enhanced thermal conductivity, reduces assembly complexity, and prevents overheating, thereby improving battery performance and lifespan while allowing for fast charging and safer operation.
Implementation Method 1
a first metal sheet (31) on an inner side of the plate and a second metal sheet (32) on an outer side of the plate, which are roll bonded to each other
Implementation Method 2
at least one cooling channel (40, 43, 44) in at least one of the at least two side walls (22, 23), the at least two top flap portions (26, 27) and the bottom member (21) formed between bonding areas (33) where the first metal sheet (31) and the second metal sheet (32) are roll bonded
Implementation Method 3
the at least two top flap portions (26, 27) are configured to elastically press the first metal sheet (31) against the plurality of battery cells (10) by inflating the at least two top flap portions (26, 27) for forming at least one top cooling channel (44)
Data Source
AI summary
A battery module includes battery cells; and a frame including a bottom member, side walls, and at least two top flap portions, which form a space for accommodating the battery cells, wherein at least two side walls are bent and extended from the bottom member, wherein the at least two top flap portions are bent and extended from the at least two side walls to extend towards each other, wherein the at least two side walls, the at least two top flap portions, and the bottom member are formed by a plate including a first metal sheet on an inner side of the plate and a second metal sheet on an outer side of the plate, and wherein the plate further includes at least one cooling channel in at least one of the at least two side walls.