Two-Stage Battery Module Cooling Path for Uniform Cell Temperature

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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 pressure drop and temperature deviations among cells.

Innovation Solution

A battery module design featuring a two-stage structure with a cooling flow path between stacked battery cell stacks, where refrigerant flows in a straight line parallel to the cell longitudinal direction, utilizing a shared cooling path and recessed parts for improved space utilization and reduced pressure drop.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a conventional battery module design is used, then the structure is simple, but the space utilization is poor and cooling efficiency is low

Engineering Contradiction:

Improvestructural simplicityVSAvoidspace utilization

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The battery module is divided into multiple battery cell stacks arranged in a segmented configuration, allowing for better space utilization while maintaining structural simplicity. The stacks are positioned to create an intermediate cooling flow path that efficiently removes heat without complicating the overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling flow path is positioned in an intermediate dimension between the battery cell stacks, utilizing the vertical space between stacked cells. This dimensional arrangement improves cooling efficiency and space utilization without adding horizontal complexity to the module structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If a conventional cooling flow path design is used, then the structure is simple, but the refrigerant pressure drop is high

Engineering Contradiction:

Improvecooling path structureVSAvoidrefrigerant pressure drop

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The cooling flow path is locally optimized by positioning it in the intermediate region between battery cell stacks, where it can efficiently contact multiple stacks. This local placement reduces the overall path length and refrigerant pressure drop without requiring a complex distributed cooling system.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The intermediate cooling flow path acts as a mediator between multiple battery cell stacks, providing a centralized cooling solution that reduces refrigerant pressure drop compared to individual cooling paths for each stack. The path efficiently transfers heat from multiple stacks to the refrigerant in a single flow channel.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If battery cells are densely packed, then space utilization is improved, but temperature deviations among cells increase

Engineering Contradiction:

Improvespace utilizationVSAvoidtemperature uniformity

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

Multiple battery cell stacks are merged into a single module with a shared intermediate cooling flow path. This merging allows dense packing of cells while maintaining temperature uniformity through the common cooling path that efficiently removes heat from all stacks.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The intermediate cooling flow path provides continuous cooling action across all battery cell stacks simultaneously. This continuous cooling maintains temperature uniformity even when cells are densely packed, as the refrigerant continuously flows through the intermediate path and removes heat from all stacks in parallel.

Inventive Principle:

Principle #20Continuity of useful action

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

Enhances space utilization and cooling efficiency by reducing temperature deviations and refrigerant pressure drop, allowing for smaller refrigerant pumps and improved assembly properties.

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

PatentUS12407042B2Battery module and battery pack including the same

Publication Date: 2025.09.02 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.