Battery Module Unit Plate Cooling for Dense Cell Thermal Control

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Solution Overview

Problem

Existing battery modules face inefficiencies in heat dissipation, leading to reduced lifespan and potential risks such as ignition or explosion due to rapid internal temperature increases during charging.

Innovation Solution

A battery module design featuring a unit plate with receiving spaces for battery cells, a connection member with a busbar and insulating bracket, and a circuit board with temperature sensors, along with a cooling system that includes a third plate with a cooling flow path to rapidly dissipate heat generated by the cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a cooling system is added to dissipate heat from battery cells, then heat dissipation efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The unit plate is designed to serve multiple functions: it provides structural support for the battery cells, acts as a connection member to electrically connect cells through busbars, and functions as a heat dissipation component with integrated cooling channels. This multi-functionality eliminates the need for separate cooling system components, thereby improving heat dissipation efficiency without significantly increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cooling system is merged with the unit plate structure by integrating cooling channels directly into the plate. The unit plate combines structural, electrical connection, and thermal management functions into a single integrated component, reducing the number of separate parts and simplifying the overall device complexity while maintaining effective heat dissipation.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If the busbar is spaced apart from the unit plate with an insulating bracket, then electrical insulation is improved, but heat transfer efficiency deteriorates

Engineering Contradiction:

Improveelectrical insulationVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The insulating bracket serves as an intermediary component that provides electrical insulation between the conductive busbar and the unit plate while allowing thermal contact. The bracket is positioned to maintain the necessary electrical isolation gap while still enabling heat transfer from the battery cells through the unit plate's cooling channels, thus balancing electrical insulation requirements with heat dissipation needs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating bracket is strategically positioned only at specific locations where electrical insulation is most critical, rather than providing complete isolation. This localized insulation approach maintains electrical safety while preserving heat transfer pathways through the unit plate, allowing the system to achieve adequate electrical insulation without significantly compromising heat transfer efficiency.

Inventive Principle:

Principle #3Local quality

3Productivity

If battery cells are densely arranged in receiving spaces, then productivity is improved, but heat dissipation becomes more difficult

Engineering Contradiction:

Improvebattery cell densityVSAvoidheat dissipation difficulty

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The unit plate incorporates hydraulic cooling channels that circulate coolant to actively remove heat from the battery cells. This fluid-based cooling system enables dense arrangement of battery cells by providing an efficient heat removal mechanism that can handle the increased heat generation from higher cell density, thus allowing improved productivity without compromising heat dissipation capability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The cooling channels are designed to extend in multiple dimensions within the unit plate structure, providing thermal management coverage to densely packed cells from various directions. This multi-dimensional cooling approach ensures that even with high cell density, heat can be effectively extracted from all areas of the battery assembly, maintaining heat dissipation efficiency despite increased cell arrangement density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 transfers and dissipates heat from the battery cells, enhancing cooling efficiency and reducing the risk of thermal-related issues, thereby extending the lifespan and safety of the battery module.

Implementation Method 1

The design effectively transfers and dissipates heat from the battery cells, enhancing cooling efficiency

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11784360B2Battery module

Publication Date: 2023.10.10 SK ON CO LTD

AI summary

A battery module includes a cell unit, including a plurality of battery cells disposed on both surfaces of a unit plate, and a case accommodating the cell unit. The unit plate includes a plurality of receiving spaces, in which the plurality of battery cells are disposed, and a connection member disposed between the receiving spaces to electrically connect the battery cells to each other.