Stacked Battery Pack Cooling Structure for Leak Isolation

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Solution Overview

Problem

Existing battery packs face structural limitations in increasing capacity and output while maintaining stability, particularly in multilayer configurations, and existing cooling systems risk leaks that can cause dielectric breakdown and fires.

Innovation Solution

A battery pack design with multilayer mounted battery modules featuring an inter-top cover part that includes a brazed cooling water passage space, separated by gaskets, preventing direct contact of leaked cooling water with cells and enhancing cooling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If battery modules are arranged in monolayer structure to maintain structural stability, then structural stability is improved, but capacity and output are limited

Engineering Contradiction:

Improvestructural stabilityVSAvoidbattery capacity

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent transitions from a monolayer arrangement to a multilayer stacked configuration of battery modules. This dimensional change allows multiple layers of battery modules to be vertically arranged, significantly increasing the battery capacity and output while maintaining structural stability through proper layer spacing and support structures.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Temperature

If cooling device is added below battery module to reduce heat, then cooling efficiency is improved, but structural expansion becomes difficult when capacity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidstructural expansion difficulty

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Instead of expanding the cooling device horizontally below a single layer of battery modules, the patent implements cooling structures within each layer and between layers. This vertical integration of cooling devices in the multilayer configuration allows efficient heat dissipation while accommodating increased battery capacity without proportionally increasing cooling device complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If cooling water distribution system is used for multilayer battery module, then cooling capability is improved, but risk of leakage causing dielectric breakdown and fires increases

Engineering Contradiction:

Improvecooling capabilityVSAvoidsafety risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent segments the cooling system into separate cooling chambers for each layer of battery modules, with independent cooling water circulation paths. This segmentation prevents leakage in one layer from affecting other layers, significantly reducing the risk of dielectric breakdown and fires while maintaining effective cooling capability for each module layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces insulation layers and sealing structures as intermediary elements between the cooling water channels and the battery modules. These intermediaries prevent direct contact between cooling water and battery components, eliminating the risk of dielectric breakdown even if leakage occurs, while still allowing efficient heat transfer through the intermediary thermal interface materials.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides high capacity and output with improved cooling efficiency and stability by preventing cooling water leaks from affecting battery cells, reducing risks of fires and explosions.

Implementation Method 1

an inter-top cover part as a cooling device interposed between the first top cover and the second top cover, and including an inter-top cover part upper member and an inter-top cover part lower member joined to each other by brazing to form a cooling water passage space inside

Methodology Applied

Scientific EffectBrazing: Brazing

Implementation Method 2

an inter-top cover part port for entry/exit of cooling water to/from the cooling water passage space

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

including an inter-top cover part upper member and an inter-top cover part lower member joined to each other by brazing to form a cooling water passage space inside

Methodology Applied

Scientific EffectHeat Exchanger: Heat Exchanger

Data Source

PatentUS12592430B2Battery pack and vehicle comprising the same

Publication Date: 2026.03.31 LG ENERGY SOLUTION LTD

AI summary

A battery pack includes a first battery module; a first top cover provided on the first battery module; a second battery module mounted on top of the first battery module on the first top cover; a second top cover provided on the second battery module; an inter-top cover part as a cooling device interposed between the first top cover and the second top cover, and including an inter-top cover part upper member and an inter-top cover part lower member joined to each other by brazing to form a cooling water passage space inside, and an inter-top cover part port for entry/exit of cooling water to/from the cooling water passage space; a lower gasket provided at a contact area between the first top cover and the inter-top cover part; and an upper gasket provided at a contact area between the second top cover and the inter-top cover part.