Stacked Battery Pack Cooling Layout for Compact Leak-Safe Modules
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Solution Overview
Problem
Existing battery packs face issues with heat discharge inefficiency, coolant leakage, and increased volume due to exposed coolant transport pipes, which can lead to safety risks and accidents.
Innovation Solution
A battery pack design with integrated cooling units between stacked modules, protected by upper and lower covers, and a coolant circulation channel within the side frames, minimizing leakage and reducing overall volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If battery modules are arranged side-by-side in a single layer, then the battery pack width can accommodate the battery modules, but the height of the battery pack is limited and cannot achieve compact multi-layer stacking
Solution Approach 1:
The patent transitions from single-layer side-by-side arrangement to multi-layer stacked arrangement, utilizing the vertical dimension (height) to increase battery pack capacity. Battery modules are stacked vertically with multiple layers, transforming the spatial configuration from two-dimensional horizontal arrangement to three-dimensional vertical stacking, thereby resolving the contradiction between width accommodation and height limitation.
Solution Approach 2:
The patent implements nested stacking where battery modules are positioned within each other vertically. The battery modules are arranged in multiple layers with lower modules supporting upper modules, creating a nested configuration that maximizes space utilization and enables compact multi-layer stacking while maintaining structural integrity.
2Length of moving object
If battery modules are stacked into multiple layers, then the battery pack height is reduced for compact design, but the battery modules require precise positioning to prevent contact between terminal electrodes
Solution Approach 1:
The patent introduces an insulating member as an intermediary component positioned between adjacent battery modules in the vertical direction. This insulating member prevents direct contact between terminal electrodes of upper and lower modules, eliminating the need for extremely high positioning precision while enabling compact multi-layer stacking. The insulating member acts as a mediator that ensures electrical isolation regardless of minor positioning variations.
Solution Approach 2:
The insulating member is pre-installed between battery modules before final assembly, providing beforehand protection against electrical contact. This prior cushioning approach ensures that even if positioning precision varies during assembly, the terminal electrodes are already protected from contact by the pre-positioned insulating barrier.
3Volume of stationary object
If battery modules are closely stacked to reduce battery pack size, then space utilization is improved, but heat dissipation becomes more difficult due to reduced airflow
Solution Approach 1:
The patent segments the battery pack into multiple independent layers with cooling channels provided between each layer. This segmentation allows heat dissipation pathways to be distributed throughout the pack structure, enabling compact vertical stacking while maintaining effective cooling. The cooling channels are positioned in the gaps between stacked modules, utilizing the inter-layer spaces for thermal management.
4Reliability
If insulating members are installed between all adjacent battery modules in vertical stacking, then electrical isolation is ensured, but the number of components and assembly complexity increases
Solution Approach 1:
The patent merges the insulating member function with the cooling channel structure. The insulating member is integrated into the cooling channel assembly, combining electrical isolation and thermal management functions into a single component. This reduces the total number of separate components while maintaining both electrical isolation reliability and heat dissipation effectiveness.
Solution Approach 2:
The insulating member is designed to perform multiple functions simultaneously: providing electrical isolation between battery modules and serving as part of the cooling channel structure. This multi-functionality reduces assembly complexity by eliminating the need for separate insulating components while maintaining reliable electrical isolation.
Data Source
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AI summary
The present invention relates to a battery pack including battery modules stacked in multiple stages, and more particularly to a battery pack including at least one battery module (100) and a pack case (200) configured to receive the battery module (100) therein, wherein the battery module (100) includes a first battery module (110) and a second battery module (120) vertically stacked above the first battery module (110), a first cooling unit (300) configured to discharge heat generated from the first battery module (110) is located between an inside upper surface of the bottom surface of the pack case (200) and the first battery module (110), and a second cooling unit (400) configured to discharge heat generated from the second battery module (120) is provided between the first battery module (110) and the second battery module (120).