Battery Module Upper Plate Integration for Lighter Multi-Block Cooling
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Solution Overview
Problem
Conventional expandable battery module structures are complex, heavy, and costly due to the need for separate insulating covers and end plates, which complicates the assembly and cooling system, especially as the number of cell blocks increases.
Innovation Solution
The proposed battery module simplifies the structure by eliminating the end plate and insulating cover, using an integrally formed upper plate to cover the busbar frames and incorporating a thermal conductive resin layer and a cooling plate with a coolant flow path to improve cooling efficiency and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate insulating covers and end plates are provided for each battery cell stack in an expandable battery module structure, then the battery module can be configured with proper insulation and protection, but the weight of the battery module increases and the structure becomes complicated
Solution Approach 1:
The patent merges the insulating cover and end plate into a single integrated component called an upper plate. This upper plate simultaneously provides insulation and structural protection for the battery cell stack, eliminating the need for separate insulating covers and end plates. The integration reduces the number of parts and simplifies the overall module structure while maintaining the required insulation and protection functions.
Solution Approach 2:
The upper plate is designed to perform multiple functions: it serves as both an insulating cover and an end plate, providing electrical insulation, mechanical protection, and structural support. This multi-functional component replaces the conventional separate insulating cover and end plate, reducing complexity and weight while ensuring reliable insulation and protection for the battery cell stack.
2Reliability
If separate insulating covers and end plates are provided for each battery cell stack, then the battery module can be configured with proper insulation and protection, but the production process is lengthened and production cost increases
Solution Approach 1:
The insulating cover and end plate are merged into a single upper plate component, reducing the number of parts that need to be manufactured and assembled. This integration simplifies the production process, reduces assembly steps, and lowers production costs while maintaining the required insulation and protection functions for the battery cell stack.
3Adaptability or versatility
If conventional end plate and insulating cover structure is applied to expandable battery module with multiple cell blocks, then the battery module can be configured, but the cooling system arrangement becomes complicated
Solution Approach 1:
The upper plate integrates the functions of both the insulating cover and end plate, creating a simplified structure that facilitates easier integration of the cooling system. The unified design provides a clearer pathway for coolant flow and simplifies the arrangement of cooling pipes, reducing the complexity of the cooling system in expandable battery modules with multiple cell blocks.
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
This design results in a lightweight, cost-effective battery module with simplified assembly and structure, improved cooling performance, and reduced part management costs.
Implementation Method 1
a thermal conductive resin layer and a cooling plate with a coolant flow path
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A battery module according to one embodiment of the present disclosure includes a cell block assembly comprising a battery cell stack in which a plurality of battery cells are stacked and a busbar frame mounted on at least one of the front and rear surfaces of the battery cell stack, a module frame that hoses the cell block assembly and is opened in the front and rear surfaces, an upper plate that covers the upper surface and front and rear surfaces of the cell block assembly; and a cross beam that is disposed adjacent to a side surface part of an upper plate covering the front and rear surfaces of the cell block assembly, and is formed in a straight line shape, wherein the cell block assembly includes a first cell block assembly and a second cell block assembly arranged side by side in a longitudinal direction of the battery cell, and wherein the first cell block assembly and the second cell block assembly are arranged separately from each other so that the busbar frames mounted on the first and second cell block assemblies face each other.