Stacked Battery Module Cooling Layout for Low Pressure Drop

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Solution Overview

Problem

Existing battery modules face challenges in optimizing space utilization and cooling efficiency, particularly in large-scale applications, leading to inefficiencies in refrigerant flow and increased pressure drop, which can compromise battery performance and require larger space occupation.

Innovation Solution

A battery module design featuring a two-stage structure with stacked battery cell stacks and a straight-line cooling flow path between them, utilizing a single cooling flow path with opposing inlet and outlet ports to minimize pressure drop and enhance cooling uniformity, while reducing the need for a large-capacity refrigerant pump.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a conventional cooling flow path design is used in battery modules, then the cooling system can function, but the space utilization is reduced and cooling efficiency is compromised due to suboptimal refrigerant flow patterns

Engineering Contradiction:

Improvespace utilizationVSAvoidcooling efficiency

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent transitions from a conventional single-layer battery arrangement to a two-stage stacked structure with upper and lower battery cell stacks arranged vertically. The cooling flow path is positioned between these stacks, utilizing the vertical dimension to improve space utilization while maintaining effective cooling through optimized refrigerant flow paths that contact multiple battery surfaces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The battery module is segmented into distinct upper and lower battery cell stacks with the cooling flow path positioned between them. This segmentation allows for optimized spatial arrangement and enables the cooling system to efficiently serve multiple battery cells through the intermediate cooling channel.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a complex cooling flow path is used to improve cooling coverage, then cooling efficiency may improve, but pressure drop increases requiring larger pump capacity

Engineering Contradiction:

Improvecooling efficiencyVSAvoidpressure drop

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The cooling flow path is pre-configured with inlet and outlet ports positioned to enable unidirectional refrigerant flow from one end to the other. This preliminary design of the flow path geometry ensures that the refrigerant travels in a straight line through the cooling channel, minimizing turbulence and pressure drop while maintaining effective heat exchange with the battery cells.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent optimizes the cooling flow path geometry to reduce sharp angles and abrupt direction changes. By designing smoother transitions and more gradual curves in the flow path, the refrigerant can flow more efficiently with reduced turbulence and pressure loss, thereby improving cooling efficiency without requiring larger pump capacity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Temperature

If multiple cooling flow paths are used to improve cooling uniformity, then temperature distribution improves, but device complexity and space occupation increase

Engineering Contradiction:

Improvetemperature distribution uniformityVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling flow path positioned between the upper and lower battery cell stacks serves multiple functions simultaneously: it cools both stacks through its intermediate position, enables unidirectional refrigerant flow for efficient heat removal, and maintains a relatively simple structural design. This multi-functional design achieves uniform temperature distribution without proportionally increasing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 space utilization and cooling efficiency by ensuring uniform temperature distribution across battery cells, reduces pressure drop, and allows for a smaller refrigerant pump, thereby optimizing space usage and performance.

Implementation Method 1

a cooling flow path located between the upper battery cell stack and the lower battery cell stack

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the refrigerant flows in one direction in the cooling flow path

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12542313B2Battery module and battery pack including the same

Publication Date: 2026.02.03 LG ENERGY SOLUTION LTD

AI summary

A battery module including an upper battery cell stack and a lower battery, each of the upper and lower battery cell stacks including a plurality of battery cells; a cooling flow path located between the upper battery cell stack and the lower battery cell stack; a housing for the upper battery cell stack and the lower battery cell stack; an inlet port for supplying a refrigerant to the cooling flow path; and an outlet port for discharging the refrigerant from the cooling flow path, where the inlet and outlet ports are located opposite to each other, so that the refrigerant flows in one direction in the cooling flow path. A longitudinal direction of each of the plurality of battery cells is parallel to the one direction of flow of the refrigerant.