U-Shaped Battery Frame With Integrated Cooling Channels
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Solution Overview
Problem
Existing battery modules face challenges in efficiently cooling battery cells from multiple sides while maintaining mechanical stability, which is time-consuming to manufacture due to complex structures.
Innovation Solution
A battery module design featuring a U-shaped frame element with integrated cooling channels and ribs, allowing for multi-sided cooling of battery cells, enhanced mechanical support, and simplified manufacturing through roll-bonded metal sheets and thermally conductive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling plates with integrated cooling channels are used to cool battery cells from multiple sides, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the mechanical support function and cooling function into a single integrated frame structure. The frame elements provide both structural support for the battery cells and contain integrated cooling channels, eliminating the need for separate cooling plates and reducing overall device complexity while maintaining multi-sided cooling efficiency
Solution Approach 2:
The frame elements serve multiple functions simultaneously: they provide mechanical support for the battery cells, contain cooling channels for thermal management, and create structural boundaries for the battery module. This multi-functionality reduces the number of separate components needed while achieving effective multi-sided cooling
2Stability of the object's composition
If a frame-like structure is used to mechanically support battery cells, then mechanical stability is improved, but manufacturing time increases
Solution Approach 1:
The cooling channels are integrated directly into the frame elements during manufacturing, combining two separate components (frame and cooling plates) into one. This integration simplifies the assembly process and reduces manufacturing time while maintaining the mechanical stability provided by the frame structure
Solution Approach 2:
The frame is divided into multiple frame elements, each with integrated cooling channels. This segmentation allows for modular manufacturing and assembly, where individual frame elements can be produced and then assembled together, reducing overall manufacturing time while maintaining structural stability
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 effectively cools battery cells from multiple sides, improves mechanical stability, and simplifies manufacturing, enhancing thermal contact and heat transfer while maintaining structural integrity.
Implementation Method 1
each of the battery cells being in thermal contact with the central portion and at least one of the two side portions
Implementation Method 2
a cooling channel for conducting a cooling fluid through the frame element
Data Source
Figure 1~2
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AI summary
A battery module (100) comprises: a plurality of battery cells (102); a frame element (106) with a U-shaped body (104), the U-shaped body (104) mechanically supporting the battery cells (102); wherein a central portion (110) and two side portions (108) of the U-shaped body (104) are different portions of a cooling plate (114) with an integrated cooling channel (116) for conducting a cooling fluid through the cooling plate (114), the central portion (110) connected to each of the side portions (108) via a bent portion (118) of the cooling plate (114); wherein each of the battery cells (102) is in thermal contact with the central portion (110) and at least one of the two side portions (108) of the U-shaped body (104); wherein the cooling plate (114) is bent in at least one of the bent portions (118) in such a way that at least one rib (120) protrudes from the U-shaped body (104).